.L5 
1921 



iclEORIC 




mm 






<^ 



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f^^ 




#: 






f^Ul: 2t. 1^?^ 



Electric Arc 
Weldin 



SIXTH 
EDITION 



fl H I.ISH E I) HY 



The Lincoln Electric Co. 

General Offices and Plant 

CLEVELAND, OHIO 




Kranch Offices at 



New York Citv I'hiladelpliia 
Buffalo Detroit 

Syracuse Columbus 

Boston Piltsburgh 

Cincinnati Minneapolis 



Hartford, Conn, 
Chicago 

Charlotte. X. C. 
Toronto 
Montreal 



A gene 



I'tlicr P) iiui'l^a! cities 



-4 



lo. 104-D 



Copyright, 1921, by the Lincoln Electric Co. 







/ 



©CU623399 



\: 



ELECTRIC ARC WELDING 



w 



/ 



c 



to divide 
ist, forge 
welding. 



i;i.l)lXG in the modern sense of the 
word. Covers a number of distinct 
operations. In order to thoroughly 
understand the subject it is necessary 
welding intd two classes of work. 

or pressure welding, 2nd, autogenous 



The Electric Ar 



t 



orse or 



Pressure Jf elding 



This term, for want of a better ime, is ap- 
plied to welding processes where two pieces of 
metal are heated to the plastic state, then forced 
together by pressure or hammering to thor- 
oughly unite them, and complete the weld. The 
familiar example of this is the weld which the 
blacksmith makes by heating two pieces of steel 
or iron in the forge fire, then hammering the 
en(K tcpgether on his anvil. 

A weld ^imilar l(i this ha^ been made fi a' some 
time li\ the use of electricity, where two pieces 
of metal are heated by an electric current, then 
forced together to complete the weld. This 
prnce>^ i^ known as butt or spot welding and is 
not the pr. ice.ss under discussion in this book. 



Aiit 



ogeno 



us Jfeldins 



Tlii.- term is .-ipplied to welds which are made 
by heating metals to such temperature that thev 
will fuse together on contact, without any pres- 
sure being applied. The ditiference between 
autogenous welds and those fornierlv described 
i- mainly the ilitterence in temi)erature of the 
metal. In the autogenous weld, the metal is 
heated to a state of fluidity and the two pieces 
flow together. 

The use of the autogenous process, however, 
is not confined to the uniting of two pieces of 
metal. It is used to even a greater extent for 
adding molten metal to other metal pieces or 
I>arts. thus building them up or tilling defects. 

Electric Arc U elding 

Electric .\rc Welding is an autogenous 
princess. It is used both for joining metal 
]>arts and also for adding or building metal 
on such parts. In fact, when two pieces 
are welded together by this process, it is 
done b}- filling in molten metal, between the 
two pieces, rather than by melting the two 
sij that they will join. 



C 



The l''lectric .\rc is formed when electric cur- 
rent is made to jump or arc from one electric 
conductor to another, through the air or some 
other substance, which is not a good conductor 
of electricity. 

A familiar examjile of this is the sparking 
which occurs when \ou touch together two wires 
connected with an onlinary electric door bell 
battery. Another familiar example is the sp.ark 
which passes between two wire terminals on the 
spark plug in the automobile engine and serves 
to ignite the gas. 

The arc or spark i^ jiroduced because the elec- 
tric current is forced through a medium which 
olTers great resisl.-mce to its passage and hnice 
produces heat. 

The object, or the conductor, frum which the 
current comes is called the positive electroile, 
the object to which it passes is called the nega- 
tive electrode. 

In arc welding, one wire of an electric circuit 
is attached to or laid upon the steel which is to 
be welded, the other wire is attached to a piece 
of carl)on or metal which the welder holds and 
wdiich is called the negative electrode. The cur- 
rent ])asses or arcs from the piece which is to be 
welded to the electrode which the ojierator holds. 
In doing so it creates such great heat on the 



\ NEGATIVE 




Fig. 1. Ill arc wekliiig. one wire (tin- pusitivel from the weld- 
ing apparatus is attached or laid upnn the steel which is to be 
welded; the other wire (the negative) is attached to the elec- 
trode of carbon or metal which the operator hohN. 



ELECTRIC ARC WELDING 



piece, thai tin- purtioii (it the piece armiiKl the 
arc actually melts and turns into vapor and the 
arc is ci intiini(iusl\ jia^sint; throujjli this va[Kir. 

The only ])in-pi>se nt the electric arc in weld- 
in<; is tn prmhice the heat fur ineltint,'" the metal. 



Advantages of the Arc 

The electric arc has no mysterious ([ualilies 
which makes it es]iecially adapted tor welding 
purposes. It is sim[)Iy the most eflicient means 
known for ]}roducin.t:;' welding' heat. 

Heat fur welding jiurpuses may he supplied 
by the blacksmith's furge tire, hy chemical com- 
bination of materials such as thermit or hy the 
burning of a gas such as acetylene in the pres- 
ence of oxygen. The heat ]>r()duced by any of 
these agencies is the same in ever ]iarticular as 
that produced h\ the electric arc: the only advan- 
tages of the arc are : 

1st — Productiiin of a Higher Teniperalure. 
2nd — Convenience in .\]iplicati(in. 
.^rd — Low Cost. 



Ar( 



Produces 



Great Heat 



It is a well knnwn fact that the highest obtain- 
able temperature can he pruduccd in the electric 
arc. In fact, a temperature can be reachcil which 
is so high that it cannot be measured with any 
instruments develo])ed uj) tn the present time. 
The reason an electric arc produces such a hi.gh 
temperature is that a large amount of heat is 
produced in a very small area. This in itself 
suggests whv the arc is the most efticient means 
of heating metals for welding. 




Kig. 2. Photograptl of EU'Ctric --\rc in operation. _ .\ large 

amount of heat is produced in a very small area, which makes 

the arc a most efticient mcatis of heating metals. (Courtesv 

THE WELDING ENGINEER.) 



Adaptability cj Different Pr(jcesses 

.\s stated above, any of the other methods (if 
producing heat will serve for welding work, but 
the difficulty comes in applying them in just the 
\\a_\- desire(l. 

The f(irge fire, for instance, serves \ei'y well 
where two pieces of metal can be placed in it. 
heated and then jiut together as they are on the 
anvil. This application is. of course, very limited. 
In fact, most welding is now done b\' the addi- 
tion of new metal between the welded pieces. 



T/ierniit U elding 

It was the necessity of adding new metal in 
certain welds which led to the (levelo])ment of 
the Thermit [irocess of welding. This ])rocess 
de[)ends upon the chemical combin.iiidii of cer- 
tain substances which produce a .great heat and 
release nidlten inm from the combination. This 
])r(jcess h.is been wonderfully successful. Its 
advantages can be readily seen in case of two 
])ieces such as a broken locomotive frame, wdiich 
coidd not b(.- ci >n\eiiienily welded by the forge 
process. 1!\ building tip a nii ild ar(.>und the two 
ends and by pnuring in the molten steel gener- 
ated by the Thermit process, new metal Cduld be 
added lietween the ends and they could be thor- 
dughly united. 

Thermit welding is in fad a casting process 
and always re(piires the iiK.ild built it]) around 
the parts to be joined and usually requires pre- 
heating of those parts in a charcoal fire or by 
,gas torches. While aii[)licable to quite a range 
of repair work, it is wA usable in the great field 
(if welding, recently dex-eloped. 



O.v.r Acetylene If elding 

(Jx}-.\cetylene \\'elding has the advantage 
over bdth forge welding and thermit welding in 
that this process can be ajiplied to any surface. 
The heat is produced by burning acetylene gas 
in oxygen gas. 

Oxy-acetylene has gradually widened the use 
of welding and has made it a common manufac- 
turing process. Even the small garage, the black- 
smith, and the jeweler can now use oxy-acetylene 
welding and make great savings over former 
methods. 



COMPARED WITH OTHER PROCESSES 





A rail which has been welded together by tlie electric 
;\rc process and is as s<ilid as a new vail. 



The cutting of metals by oxy-acetylene is an- 
olhci' ticlil which has been very wiilely ilevelopcil. 
]t i-- u^cd for cutting up scrap, fijr wrecking steel 
sirnctnres. liridges, vessels, etc.. and is wiihout 
aii\ ri\al as far as speed is Cfincerni-d in Ibis 
lield Ht wiirk. 

There are niaii\' places, In iwe\ci-. whc-re e\'eii 
acetvleno welding cannot l)e ccuneiiieiitly or snc- 
cessfulh' applied. In the first place, the heat <d 
the acetxlene torch is spread nver a relatively 
wide area. The greatest heat in ilie acetylene 
torch is priidnced at a ixiint in the inside nl the 
flame priiper. .and in order to get this point down 
tri the metal, it is necessary i" hold the flame 
ver\ eliise so th.it it s])reads out over the surface 
of the metal to a considerable degree. 

In welding steel sheets or ])lates. for instance 
this causes a great deal of difflciiltx, owing to 
the buckling and bulging of the sheets, pmduced 
bv the wide heating. 

At a recent convention of the Railway Master 
Blacksmiths' Asosciation, Joseph (jrine, of the 
New \'cirk Central Railroad, in discussing this 
pi.iint sa\'s, "In welding boiler sheets the electric 
])rocess is su])eri(ir to oxy-acetylene because the 
latter generates too much heat and causes the 
sheets to buckle," 

In another discussion of this same subject at 
a (General horeman's Convention, J. M. Kerwiu 
of the Chicago, Rock Island RailnuKl. says, "We 
use the electric ami oxy-acetylene jn'ocesses. and 
have found that the electric is the best for weld- 
ing patches and cracks, and oxy-acetylene is best 
for cutting-." 




Fig 4 \ rail wlucli lias been ucldL-d together by the ...xy- 

acetvlene process bm owiiis m the severe contraction of the 

iiutal nil cooliiis llie rail has broken. 

Still another expression of oiiinion is given 
hy the Committee On Design, of The .\iiierican 
Railway Master .Mechanics' .\sosciation, who 
state, in their reimrt. "l'"roni the reports received 
from different roads, they indicate that consider- 
able dirticulty is experienced from welding flues 
with oxv-acetylene process, while roads using 
the electric process report very satisfactor_\ re- 
sults." 

These opinions from railway men, are given 
at length, because of their very wide exiK-nence 
with welding processes. 



Safety 



.\nother factor which enters into considera- 
tion of the .acetylene process is the matter of 
safety. It is not to be denied that there is a 
great element of danger in the oxy-acetylene 
welding process, particularly where a generating 
plant is used. 

At the meeting of the West Coast Safety En- 
gineers' Association, in San ITancisco. January, 
1017, K. L. Hemingway, of the Industrial .\cci- 
dent Commission of (alifornia, called particular 
attention to the possible small amounts oi hydro- 
gen existing in the oxygen gas and this commis- 
sion has issued a w.arning to the public not to 
use oxygen gas, for acetxleiie welding, unless 
absoluteh' assured that it does not contain more 
than 2'r of hydrogen gas. 

These matters .are not brought up in aii\- ettort 
to discredit acetylene welding, but because they 
are necessary to any intelligent practical con- 
sideration of the subject. 



ELECTRIC ARC WELDING 



Arc Jf'cldiiig is Convenient and 
Safe 

Xow let us compare arc weldinsj- with the nther 
prucesses. as to convenience anti safet\'. 

Arc wehlinsj; can he apiilied anywhere that 
electric cnrreilt is a\aihihle ur can l)e s^enerated. 
and where an electric cahle can he carried. It 




I'iL:. 5. Arc WV-Min^ can In- nppli li anyulun-. wluie an lU'cliI 
cable can he cmu-'l ami is llu- iiiivi cuiiv fiiiciit 

i.t all foMiis .il ui-MiiiK. 



can he n^ed inside linileis and lire hoxcs, in shi|) 
holds, peidiaps the must inaccessible location that 
can he imatjined. ( )w ini; In the action of the 
arc seams. i.'tc., can he welded n\ i.-r the he.id (j1 
the (i]ieratnr with n(.i;ieal dilticnltv. 

I'.lectric arc weldnit; can lie used for jniniiiL;' 
])arts. for hnildiilL; in molten mel.-d or for huild- 
ins,^ u)). 

W ith a])]iaratns of the proper design, arc weld- 
ini.; is the sim|ilest weldini;" process in existence, 
ii ret|uires a minimum ol preparation. I'reheat- 
niL; of the parts to he welded is necessary onl\- 
in the case of his^di carlion steel or cast iron. 
The heat is apjilieil on a ver\- small area, so that 
there is no liucklinj; or undue exjiansion of sheets 
or plates. 

1 he steel lor hlliu!.; in or huildinij on is |)ro- 
tluced hy the meltini,' of the electrode which the 
O]ierator holds in his ri^ht hand, thus the left 
hand is always free for placini; of ])arts and 
adjustments, niakinsj the process practically con- 
timions. 



There is ahsolutely no dani^er in the operation 
of properly constructed electric arc weldint;' ap- 
]iaratus. 

The voltat^e em[)loyed is very low, in fact 
l(jwer than that of a residence lighting system, 
and cannot h\ any possihilitx injure the ojierator. 

Com p>arative Cost of Arc U\ldni<{ 
and Acetylene Jf'elding 

It is not necessary to discuss the forge weld- 
ing process or thermit welding, as to cost. In 
each of these jirocesses the cost of pre])aring the 
parts for welding is very high and neither i>\ the 
|)rocesses are usahle except in certain limited 
.•ip|)lications. 

The i|uestion of cost n-siilves itself into a com- 
parison of electric arc welding with o.w-aceiv- 
leiie. The simple fact that the electric arc pro- 
duces ;i higher temperature than the acetylene 
gives the arc a decided advantage. 

I'erh.aps the hesl comparison can he ohtaiued 
h\ giving actn.al figures on such operation-. ( ine 
large manntacturer ol tanks ;iiid similar prod- 
ucts, employs both oxy-acetylene and arc proc- 
esses and has tna<le careful comparisons of cost. 
The report from one particular test made on 
identicallv the s.mie work is summarized helow 
and shows eoiiclusiwly that the .arc will weld 
this tank at less th.iu one half the cost of the 
acetylene jirocess. 

Ohjects Welde.l: .Si.x _'15 gallon lank-. ,-'i'' 
shell, i'." heads with oue .V' anil 2" .and I'.;" 
standard couplings. 



}-iJbi^ 
i-3 PIPC 






-rCET WELPEf 
LOna iCflM 6.69" EOUflLTO 3'».S F 
iBCULflR StflM IJ.7'10" ■ ■■ 31. 

COUPLIMCS 6 . ?.' 0" " ■■ 12. 

10r«L FOB 3IX TflriKS 
5-2 PiPC COUPLIHG 



140.S FT 




215 dflLLpn Tfl^K 



.'15 I. .ill. Ill I'.nik nil which 
m,Tte. 



cninii.iiative cn-t 



COMPARATIVE COSTS 



Acetylene Welding 

W'cldiiii,' < hitlit: — Statimiary tk-nerator. No. 2, 
Welding torcli number 7 and 8 tip. 

Time of wcldinji. 18'.( lirs. (li, 30c per lir $ S.7S 

Oxygen criiisunied. i~\ cii. ft. at .Ol.^Sc 5.(K)8S 

Acetylene consumed i2.S cu. ft. nt .IHISc cu. ft. . . 2.60 
Filling material, \Si4 lbs. at 12o |)c r II. 1.89 

Total cost for I] t.iiik^ $15.2785 

Cost <>/ a'l'ldiiiji I tiiiik j'.j;./ 



Arc Jf elding 

\\ eldinn ( )uirit — Transpi irtaiilc t.vpc for one operator, 
maniifactmrd liy Tlic Lincoln Klectric Co., Cleveland. 
Ohi.i. 

Time of ueldiii.i;. 14 lirs. (ii 3(lc per lir $4.20 

Kilowatts consumed. 60 kilowatts (a 2c per 1.20 

l-'illin.i; r.id used. 17 U.S. (<V 1 3-lOc 1.97 

Total CMSt ..f tanks $7.37 

Cost <'/ lycldtv.ii I lank I..^J 




Tiu- l\ail\\a\' KIcctrical luigineers' As.sociati<.>ii 
liave niailc a very careful investigation of this 
subject, since the raih'oails use weldin.g to an 
enormous extent. Their committee on this sub- 
ject reporting at their \'^\() Cnnvention, states, 
"Three kilowatt hmirs of electric energy (cost 
6 cents) will pruilucc the same amount of heat 
as niav be i.roduced b\' ap]iroximatelv 6-')/10 
cubic feet of acetylene (cost ll'j cents) ami 
7-?/]0 cubic feet of oxygen (cost 13 cents)."' 

The parentheses in the abo\e quotation are 
our own an.] they indicate the l'^16 prices of 
electric current, acetylene and oxygen. The same 
ratio would still obtain. It will be seen that 6 
cents ex]iended in electric energy will do the 
same amount of welding worlc as 26' < cents spent 
for oxy-acetylene .gas, on the assumption that 
the two jirocesses make equally effective use of 
the heat produced. 

This assumiition, however, is not in accord- 
ance with the facts, since it can be shown that 
on any welding operation, the heat proditced by 
the electric arc will be at least three times as 
effective: that is, three times as much welding 
can be accomplished with it as can be done by 
the same amount of heat produced by the oxy- 
acetylene torch. 



liil. 7. *!;i- tank made b.v the P.iu.ni nailer & Wcldei- Co., 
t K\clc-iiid. This t.ink has het-n made Imih h.v arc welding and 
ii> acetylene weldini;. The arc wcUiint: cu^t^ '4 to ■ ,i as much 
.t- 1,'as welding. The tank is tested at l.^'l Ihs. water liressure. 




Ti;;. S. .\ ,adi..t.ir uvlded by the St.ni.laid Oil Cu.. of Indiana. 

("i.mpai ati\ e custs by .Acitylene and .\rc Welding were 

as follows: 



Cfsl of Ac-tyleiu- U'cl.l 

4(1 cu. ft, ;ic,l\I(ne al 
-tS cu, 11. i>.\ygen at 
2 hr--. time at 



C'.vf ,./ .tdiiii- r, illi F.h 



R.uUalors 

111 $ .411 



Weld 



1(. K. W . 11, at $ .(Mil, ,,er K, W, H. $ .1(1 

2 hr-. tune at .4,^ j.er hr. .*Ji3 



ELECTRIC ARC WELDING 



The ^anie coniniittee suljiiiitted tn the C'lnveii- 
tiun, a chart which is i-o|irnihiCf<i mi i<a£;e 7. 
showint; the cost cuniparisi )n l)et\\een gas and 
electric weldiiiL;. ha^eil nn the anniiint nf heat 
produced. 

The tal)le nn i^a^e (i shows a complete coiii- 
]iarisoii of costs cniupiled hy an engineer, who 
has made a special suhject ot' welding, in a num- 
her of (htferent fields. 

( iordon Fox. writing in the K.iilw.ix .Mechani- 
cal Engineer, \o\eniher. I'Md. --nm-^ the wIkjIc 
m.itter u]) as follows : 

"Inr work (in liiM^^. bronze (U' aluminum the 
ox\ -acet\lene tl.ame has ni_i (-(impetitinii. ']"he 
main point of superiorilx nf the arc method i^ 
its economy, as the electric nvc produces the 
necessarv he.at at ,i much Imver co^t than doe~ 
the oxy-acetylene thime. In its field, the arc 
also produces results as good, if not hetter. than 
can be obtaiiK'd witii gas. i. e.. t1ue-welding. etc. 
To avoid e.xcessive cost, predicating is almost 
always necessary in gas welding, but may often 
be dispensed with in .arc welding. The cost of 
electric power for a welding iob will onh' be 
from 15 to 25 i)er cent of the co-t of oxygen and 
acetylene for the same job." 



It will lie seen from .a careful study of the 
alio\e authorities that arc welding is beyond 
(|UfStion far more economical than acetxleiie 
welding, where a large amount of wi>rk is to 
lie done. 

In .a sm.all shop, snrh as a .gara.ge <ir hlack- 
smilh. or in an\ place where weldin,g is onl\ ilone 
at long inter\.ds. such as re]iair worl< in machine 
sho|)s. the acet\lene process has the adv.inta.ge 
because of the low first cost of eipiipment, 

W herever there is work enough in a commer- 
ci.d welding shop (o keep two or three oper.itors 
coiitiiiualh' bn->\". .arc welding will show a sa\-ing 
gre.at enough to pay for the addition.d cost of 
ei|uipment in ;i \er\- short time. 

In ,a m.inufacluring plant where the wurk cm 
be done with the arc. it will sometimes pay to 
in-l,all an arc welder when there is only enough 
w I iid< t(j keep :in oper.ator lius\' with the gas torch 
hw homs per day. 

W bile some saving" ma\ bi' made in acef\ lene 
welding, by .generating the acetylene at the plant, 
a good generator for this purpose will cost (|uite 
• i-. much .as arc welding apjiaratus. and acetylene 
welding will still cost twice as much as the arc 
process. 



T.AHI.K OF COMI'AK ATI\H WKLDINC; COSTS— MET.\L SUHKTS AND PL.ATKS 
i'. ASKO ON FIGURES IN YEAR 1919 



.^cctvlcNc U'rhiniu 



.-Ire Jf'cldnuT 



n,. 
x... 

1 


ThickiH-s, 
-f Metal 


Cu II, 
.VclyloH 

i2\ 


PO JKHlt 


•1, uil.i 
|,oln 


li.st 

..f i;.-is 
.14 


|-..i,,l I-.,- 
.74 


C.-l pi-i 

Wcl.lol ft, 

,(12 


\lll|HM- V 

ni .\r. 


K \\ . 

Inpn' 

\i i; s. 1 


C.-l ut 

r.,uiT 


I'l, 

\\>l,(e.l 

|)|T 111. 


1 .,l:.l 
Co-l 


( .>sl iicr 

fi, u.i.i.-a 


•> 


iV 


4.'^4 


.S.50 


2^ 


,21 


.81 


.03 


30 


3.(1(1 


.(If) 


25 


.66 


.026 


3 


Si 


SM4 


9,28 


20 


_,i5 


,95 


.(15 


6(1 


3.08 


.(16 


20 


.66 


.033 


4 


M 


l-'.5ii 


14,27 


l.i 


.."^.^ 


1,13 


.(18 


8(1 


3.2(1 


.116 


15 


.66 


.044 


5 


f.; 


i;.si 


21. .?2 


I) 


./ / 


1.37 


.15 


'III 


3.52 


.07 


Id 


.67 


.067 


6 


J-4 


24.9; 


28,46 


() 


1 On 


1,66 


.28 


lie 


4.15 


.08 


8 


.68 


.085 


7 


A 


o3,24 


37,9(1 


; 


1,41 


2,01 


.41 


12(1 


4.^(1 


.O'l 


.s; 


.69 


.086 


8 


Vi 


41,99 


47,87 


4 


1 78 


2:3,S 


.6(1 


14(1 


4.75 


,16 


5 


.70 


.140 


9 


'j 


.".85 


').r9.s 


.> 


2.4.^ 


3.(15 


1 ,02 


' l.-(l 


5.75 


,12 


3 


.72 


.24<:> 


1(1 


•\s 


82. .ill 


94.().s 


J 


3,4(1 


4,(1(1 


2,(KI 


16(1 


5,85 


.12 


3 


,72 


.240 



Alii'VL- il.ita bascil ' -n fiilLuvin.;; o■■^t^: .\cetyleiie 2'4C i»r cii. It, (Iwycii l-^c |itT cu, ft, 
I'.mcr 2c per K. \\'. Hr, L.tIlt 6(Ic iier Mr, 
Calorific valm of .icetylciit i> 1555 I'., T, 1', per cu, ft. ( ine f\. W . Hr, i> i'.|iii\ .ik-iit to ,^413 1'., T, I 



CARBON AND MM AL hLh( 1 RODl S 



3S0 



30C 

zeo 

S zzo 
\ 

V 

O 200 






110 

I 

< 100 

■K e,o 
I 

iO 
40 

zo 



10 to 30 10 so 60 lo BO 90 !00 
Heaf Un'tfs Per Hour- B.T.U. -r WOO. 

I'ig. ^V Cnr\es showing llu- C'imii.irison between c<wl .if y;;is an.l 
fl-clrie WfliliiiR based on the number nf heat units per hiiur. 
Taken inmi Assoeiation "f Railway Kleetrieal Knsiiieers Nefoit. 



Civhou and Metal FAcctrodc 













M M M 1 M 1 1 






J 


/ 




- 


— 


Acetijlene Oas. J if per cu. ft 
Oxyyen Oas Zif - - - 
Poner, li per KtvH from 
75 Vol f Line 






/ 


/ 






1 




/ 








/ 


j 








,/ 


/ 


1 




































/ 


/ 








750 






























t 


/ 




































J 


1 






































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litat over a lars^c area. Such work would be 
tuuiul in the filhnti in "1 lari;e holes in castings. 
'i"he carbon arc ileniands fnmi 300 to 600 am- 
peres of current and the heat produced is so 
intense and the i^dare so blinding that the opera- 
tor must wear gauntlet gloves and a shield coni- 
]iletelv Cftvering the head and shoulders. 

The metal electroile process is used for 90 per 
cent of all welding w.irk. The heat is only 
spread i>ver a very small area, enabling the 
operator to deposit the metal very accurately on 
edges of sheets, i)lates. etc. This process re- 
quires .^0 to 250 amperes current and since the 
heat is not so intense the head and shoulder 




Fig. 1(1. Carbon Electrode Welding. The operator holds the 

carbon eleelrode with the rishl hand and feeds the filling metal 

into the weld from a r..d held in his left hand. 



In electric arc welding there are l\\<i distinct 
proces-es. In one, the electrode manipulated 
bv the operator is a carbon pencil, from ' ; inch 
to 1 ' _. inch in diameter, and (i to 12 inches in 
length, pointed to bring the arc into as small 
a space as ])0ssible. The carbon arc is simp'.y 
used to sujiply the heat and the oper.itor feeds 
in the tilling metal from a melt bar held in his 
left hand. 

In the other jirncess. known as the metal elec- 
trode process, the electrode is a metal wire of 
comjiarativelv small diameter and this wire grad- 
ually melts itself away, furnishing the metal for 

filling. 

The carbon electrode process is onl>- used 
where it is desired to do fast melting and to 




tig. 11. .Metal Electrode Welding. The electrode in this case 

is a metal wire of small diameter and this wire gradually melts 

itself away, furnishinK metal for the weld. 



ELECTRIC ARC WELDING 



pliield is lint necessary Inif a face shield with 
colored t^lassi'v can he \\(jrn in^'tead. 

The (jne^tion ut whicli |)nice--N {n iisc is de- 
lerniined entireK li\ the w nrls 1m he done and 
a good idea can he nhiained h\ ^mdying tiie 
various a]ii)licatiiins cit weldin.i; ]>re^ented later 
in this 1 k. 

()p>c)(iti())! oj Electric Arc 

(jeneralU speaking;, no L;re:itei' skill is re(inii'ed 
in the oi^eration of the electric arc than would 
be necessar\' in an\- other modern uiannfacturinsj; 
process. An intelliijent man i an k'aiii to do 
simple weldint; wiirk in from iwn da\s to a 
week's time, dependint; on the nature of the 
wdidv. Great skill is ol course ac(|uired 1)\' prac- 
tice. Electrical knowledi,'e is not neces-,ar\-. The 




^lii'uv ;iri .nniatuif sluift uliiclj l):!s been .wurii in service, then 

lunlt M|' !)>■ welding .11 new -leel. The new steel i^ tjei-.ig 

l.iineil ilnwn t.' ^i/e in th.- l.'ltht . 



a]}])aratus now available for this use practically 
never neeils attention and can be operatetf with 
less care than almost any machine tool u^ed in 
the modern shop. 

Characteristics uf the Jf'eld 

It shoulil never be overlooked in considering 
welding that the new metal in a weld is simpjv 
metal which has been melted and cooled again, 
ami it partakes of the properties of a cast metal 
rather than of rolled or wrought metal. 

I"or instance, in weliling two jjieces of boiler 
plate the weld will have just as great tensile 
strength as the original jilate. but being cist steel 
it cannot have the ilnctilit}- which rolleii steel 
stock jiossesses. The cast steel in the weld mav 
have the jirtiperties of ingot steel so tar ,is duc- 
tility is ci mcerned. 

It Hscil to be conuiion opinion that .i welil 
could not be maile which could be readiK- m.i- 
chined. hut this mistaken imjiression has long 
since been corrected. 1 he wehl, when properh- 
maile, can be machined as readil}' as an\ steel 
casting or flange steel. 

Welding has bei'U tised to such an e.\lem !■ ir 
repairing bre.ik.igt' ami tiefects that nidess tlntr- 
oiighly posted, the a\erage man is a|it to look 
upon it as a "patching" or "doctoring" jn'ocess, 
whereas it is accepted in the most adsanced 
eiii^incering practice and is useil to a wonilerfnl 
extent in automobile, locomoti\'e and other eoii- 
stinction of the hi'diest character. 




Fig. 13. Electric .^rc Welded Automobile Re.ir .\?cle Housing. 



DDiNiHHiiHM)iiiiiiitiiiii!(iiiniDniuitiiii)iuiini]i[iini>i 



CHARACTERISTICS OF WELDING 



Applications of Arc Weldin; 



It is beyond the pow er of any one man and cer- 
tainly beyond the Uniits of this bonk to j^ive an 
adequate idea of the applicaticms of electric arc 
weldins;. 

W'itliin the last few years the ai)i)aratus f.ir 
this pnrpose has been highly perfected. Such 
enormous strides have been made in its applica- 
tion and use, that it is difficult to see any limits 
to its adaptability. 

The following pages are intended as an outline 
of work which has actually been done. To any 
one interested in applying the process to his 
l)roduct, the best advice is to consult an expert in 
this line of wurk as to the feasibility of the par- 
ticular job he has in mind. 



Jl'liat Mcftils Can be JFeldcd 

Electric arc welding is mo^t successful on 
steel, iron and the various alloys of these metals. 
It ha- l)een applied with great success to the 
welding of cast iron in various forms but cannot 
alwavs, because of the great heat produced, be 
used on cast iron where the sections are thinner 
than '4 inch. 

The arc is not jiracticable for welding .alumi- 
num. Acet\ lene is the best process thus far dis- 
covered for this work. 



G Clio III Rule 

Wherever steel or iron parts are to be joined 
or breakage and wear of such parts rejiaired, 
there should at least be a careful investigation 
of the possibilities of arc welding. It can be 
stated with certainty that any job of this char- 



acter which can lie dime with acetylene cm be 
done at lower co>t and at greater speed witl-. the 
electric arc. 

While the following pages do not repre-ent 
one per cent of the total possible applications of 
this process, they will serve as suggestion- to 
manufacturers and others interested in the high 
development of iron and steel fabrication. 




Fig. 1-). Electric .\rc Welder used by the Standard Oil Co.. 

to caulk leaks in vapor lines and oil stills. The vapors are very 

inflammahle and every joint must be absolutely ''ght.^ hence 

welding is used in ::ddition to rivetiuK. (See Fig. 7j.) 



ELECTRIC ARC WELDING 



Steel Foundries 




I'ig. 15 liliins l>l<iw hole 111 a rasl sU-rl ni'itur truck wheel. Ihe^e ca^tini»s, thiuiyli subject tn severe strain, were approved tor 
use ill niilit.iry int'tur tnieU-« when defects were lepaireil with the elictiic arc. 




The fir.>;t large commercial nst.' itf arc weMin;,' 
was in the repairing; of defects in steel castiii<is. 
The manufacture of these castins^s is a most 
difficult jirocess owiiii; to the hiijh melting point 
and the difficulties of pouring molten steel. 

Even in jiouring- the straight steel ingot, it is 
ditticidt enough to secure a souml ingot, owing 
to the gases which are given off, causing hlow 
holes in the castings. In the more com])licated 
sha]ies in which steel castings are made, it is 
alnio>t impossible to produce a large run of cast- 
ings without sand sjiots, caused li\- the washing 
away of jtarts of the mold, iir hlow holes caused 
by the formation of gases, h'ven where the cast- 
ing is otherwise souml. the excessive shrinkage 
of the steel frequent'y causes shrinkage cracks 
to appear or causes umlue strains to be set up 
in the inside of the casting itself. .\ few vears 
ago. automobile construction ;ind refinement in 
agricultural implements and other lines greath' 



incie.ised the demand for steel castings. Large 
numbers nf these castings had small defects 
which did not seriously alifect their strength, but 
did impair their ap]iearance. The high cost of 
the steel castings and the percentage of waste 




Fig. 17. Steel truck wheel casting (disk type). The defects 
ill this wheel were found after machininR had I)een done, and 
were perfectly welded and repaired with the l-incolil Arc Welder. 



10 



STEEL FOUNDRIES 



led some one to hit ui)on the electric arc as a 
nictliod of rej)airin<j these minor defects. They 
reproduced on a small scale the conditions of the 
electric furnace. It was a ]ierfectlv lo^jical ci in- 
clusion that if steel was niellcd and imured into 
these defects, the defect wnnld he hlled with 
cast steel which would he in every way as !;(»'d 
as the rest of the casting. 

It was not long liefore the steel foundrynian 
and all users of steel castings liecanie ccmvinced 
of the merits of this process and castings with 
defects repaired in this manner were accepted 
and used without i|uestii'n. as heing in every way 
ecpuil to castings which came perfect from the 
mold. 




Afl 



tiK. I'^. Steel Pulley t acting on wliieh .1 ileficlive hosi 
rei'.'iireil liy huililiiiK iiji will) the arc weMcr. .\ slirinka 
iti the rim liatl .ilv.i been rci'.iiieii liy arc weMin 



lieeii 
ci ack 



Better Deliveries 



This use of the electric arc has not only saved 
great sums of money for the steel foundrynian, 
hut it has greatly improved deliveries of castings. 
Formerly, the foundrynian coulil not ahsolutely 
assure his customer that all of any given ilay's 
production could he counted ujion. but with the 
introduction of the electric arc. defects are 
qiiicklv repaired and delivery schedules can thus 
he accurately maintained. 

Manufactiu'ers who use steel castings fre- 
quently find it advisable to install their own weld- 
ing outfits, thus saving the return of the castings 
to the foundry when small defects are cliscovered 
in machining or in testing. 

In face of the traffic conditions recentl\' exist- 
ing one firm found it very profitable to install the 
arc welder rather than to ship the castings back- 
to the foundrv tliirtv miles awaw 




IIef«-u e 



Afle 



I'ii.,'. 1^. Large Steel Gear showing shrinkage crack uhich 

uiinli] have made it necessary to scrap the casting had it not 

been for are welding. 



The use of the arc welder saved both iiK.iney 
and time. 



Less Ski Heel Labor 

Electric arc wekling has also relieved the labor 
situation in the foundry. It has become harder 
and harder to secure skilled labor, especially 
molders. for this work. The supply of such men 
does not keep pace with the increase in demand. 

Under former conditions it was useless to put 
an apprentice on such work, as the material he 
would spoil and the floor space he would occu])y 
would lose for the foundrynian far mon- than 
it would gain for him. 




Befor 



After 



hig. 20. Motor Bracket Steel Casting from which a riser has 

been cut with the are welder. This cut was through about 3 

inches of steel and took api'roxiTnately six minutes. 



11 



ELECTRIC ARC WELDING 




I'lK'. Jl. Large ;»tcel c.i.-.uilK i^iJ.iliLii b> a:^. Atldiiig .illci U 

liad I)i*L-ii in service. 

Thj'v lia« also been repairecl nnce by riveting. Note }iow much 

cl:aner tbc uehled job is. 




1-iL- 



Kepairiiic (Ict'ccl in 1.11 m- c'i--tiiiy uiili .1 Lincoln Arc 
Wcklei. 



\\ ith the electric arc. however, the mistakes 
whicli the heginners make can in nine cases out 
I if ten he renie<hed anil one or two welders can 
take care of the work fi>r a fairly large foundry, 
even where the prujiortion of cheap help is quite 
high. 

As has heen stated, arc welding is not in any 
sense a "patching" or "doctoring" process. The 
defective jiarts of the c;isting are melted and cast 
again in solid steel. These welded parts are just 
as strong as an\' other jiortion of the casting 
and when the work is carefully done they nia- 
clnne and finish perfectly. .Man\- steel foundries 
wltere welders are in u^e arrange to take hack 
castings which have shown defects in the ma- 
chine sho]) and after welding them return them 
til the customer. 



Opicnitioii of Arc 



It is easy to prevent the usual trouhle due to 
the So-called "chilled" or hard weld, hy applying 
the aic for some minutes tn the part t'l he welded, 
lliu^ thnroughlv ])redieating the surrounding 
metal. When the welil is made the whole m.iss 
llun ccKils (ilY slowh- and the sudden chilling uf 
the new metal is a\'oided. 

The arc can he used fijr pre-he.ating the cast- 
ings in exactly the same manner as the nxy- 
acetylene flame is used. 

Siiiuetimes a slag cnvering is pro\ide(l to ex- 
clude the air from the molten metal and thus 
prevent the ])resence of oxide in the finished 
weld. This is onlv necessarv in s[)ecial cases. 

\\\\\\ these simple |irecautions any steel foun- 
ilry can use the arc welder successfullv and save 
many castings that would otherwise he a dead 
loss. 






.\;c Welders at the pbiu 
Co.. Easton. Pa. 



Lin. 



Defective pulley casting. Repairin,g tliis with 
iln .\rc Welder saved $10.J0 in 10 miiuiles. 



12 



STEEL FOUNDRIES 



Jf'elds Easily Mdchincd 

'J'he wfUi in tlio castiiit; is as suft and is as 
readilv macliined as any other ])ortinn of the 
work. Idle l)lo\v holes or shrinkage cracks, sand 
holes, etc.. are first predicated 1)\- playint,' the 
arc over the surface, holding the casting in such 
a position that sand and foreign matter will he 
flushed I'Ut. This work is done with the carbon 
electrode. The filling material can he obtained 
from steel wire, especially made for the purpose 
or even from steel scraps or bars of suitable 
analysis. Burning out sand spots with the oxy- 
acetvlene Hame is impractical, because the re- 
flected heat burns off the end of the tip. Where 
the "xy-acetylene flame is used, it is necessary to 
chip out sand spots with a pneumatic timl. which 
ni.-ilsc^ the cost of tlie operation very high. 

Electric Steel Eouiidry 

The electric steel foundry can use electric arc 
welding to particular advantage. In these cast- 
ings, the metal electrode process will ordinarily 
be best suited. The defects can be chipped out 
with a pneumatic hammer and since they are 
nut large, can be readily rei>aired with the metal 
electrijile. 




Kig. -M. I.incoln .\rc WcUk-r 400 ampere capacit.v installed in 

the plant of The Standard Steel Castings Co., Cleveland. O. 

In the background i; space provided for the installation of 

another welder. 



Sizes of JFelders 

1 he size of welder adapted for certain work is 
a matter which should be passed on by the m;uui- 
facturer of the apparatus. However, certain 
general sizes can be suggested. 

T'or steel foundries using the metal electrode 
or very light carbon electrodes on small work, 
a welder supplying 200 amperes will usuallv be 
sufficient. This is an ideal size for the electric 
steel foundries. 

For the foundry making castings up to 1000 
pounds, a welder should be used which has a 300 
ampere capacity. For the very large foundry, 
where large work is produced a 400 ampere 
welder is the ideal size, and is arranged si) that 
two or more machines can be connected together 
in parallel, thus giving the current for heavy 
carbon electrode cutting. 



Equipment 



See page 4(> for illustration 
suitable for steel foundries. 



of apparatus 




'■■■^■. 



I'illing ii 



!il-.\ ii.ilc in a steel casting by 
Electrode process. 



13 



ELECTRIC ARC WELDING 



Grey Iron and Malleable Foundries 




tl.-l! 



M.ilI.nWc In.n I'.rakc SpiiU-r .m which iMit ..f lh<- 
t 'T" u :is ini^'-iiiK. This was readily tilKil out liy wrlil 
\li.Tr nu-chanical repair wunl.l ii'M ha\c htiii practical. 



O" 




i-is. 



AuI'Miii.'liilt' parts siuiwiiig slit;lu ilffcct^ \vhii.ii lan ln- 
n.-nu-'Iict] by Arc WeUlnij;. 



.^^^ 



The use of electric arc wekling has heen ex- 
tended to grey iron and malleable casting's to a 
verv large extent. There are many minor defects 
in Ixith gre\ iron and malleable castings, which 
mar the ajijiearance of the casting hut do not 
seriously affect its strength. These can be re- 
paired and filled to good advantage with the arc 
welder, unless the castings are very thin. 

The .liiicricaii Machinist says: "The arc elec- 
tric weliler is used on malleable iron castings for 
t\\(i |iur|>iises: l^'irst, for adding material that 
has been either swejH away in the mold or is 
lacking because of a mistake in the design, and 
second, to save castings that have blow holes or 
sand holes, If metal could not be added to make 
a S(.und rejiair, castings wnuld often have to be 
scra])])ed : a ])Oorly patched casting woitld be cmi- 
(jemneil for appearance sake, and one witli un- 
sound i(mit> would be weak and tend tn frac- 
ture." 

The difficidty encoimtered in welding cast iron 
arises from the expansion and contraction of the 
local area heated by the arc and the tendency 
of the weld to become hard when the casting has 
cooled. With the jiroper equijiment for pre- 
heating furnaces and with skilled oj^erators it is 
probable that 80% of all grey iron castings can 
l)e welded using the carbon electrode process. 
The metal electrode process is ver\- difficult to 
ir-e on cast iron because of the extremelv small 
area heated by the arc. This, of course, would 
be an advantage in welding any other material 
than cast iron. 

The Welding F.iigineer says in a recent article: 
"Welding cast iron with the electric arc jirocess 
will become a very cmmon practice within a 
few years." 

The grey iron or malleable foiunlry ctmtem- 
plating the use of arc welding should call a weld- 
ing engineer and consult with him as to the 
possibilities of the jirocess on the jiarticular class 
of WMj-k which thev desire to do. 



■««• 



Fiv:. -8. Same jiarts 
facc~ are gruiitul nlY 



4 



; sliowii ill Lit;. 27, .ifttr ut-liliiitj. The 
lean and no difticuliy \\a-> cxperit'iiced 
in machining. 
llliist'-atious Coii'tt'sy AMERICAS MACiUMSTl 



e.;i*:j" 



V 



^- 



Fi.ii 2*^. Malleable Iron Switch Stand showing a defect which 

V :v sufticieiit tn reject it for appearance sake, but which was 

readily remedied by Arc \\"elding. 



14 



iliiianiiimmju,;..' i ^w9Wllml^^llKlMll(|ll|l|(|lll!ll|||illmllffil'J|||l(lL'l:UI\l^lLt^;:.l^;4lIrall[l;lMilIlllluulllIm:'^^lK;v!:;;^.!!lM 



ELECTRIC ARC WELDING 



Railroad Shops 




liii 3lK Wcldini: a loconii>ti\e Iiaiiie u^ni^^ a p-ntaliie l.inc.In Arc Welder. The same week that tin^ pimtw was taken $6 000 

was saved tliroiiiih arc welding done on this welder. 



Next to the steel foundrv, the railroad In< 
probably made the widest u>e of electric arc 
welfliiig;. 

Mr. F.. W'aiiainaker. F.leclric I'.ni^iiiecr nf the 
Kiick Island R. R.. receiit'\ in a \ery interest- 
inj^ article in the Railway h^lectrical lMis:;ineer. 
anioiiij other tliing-s. savs : "r)ur fi.ijnres show 
that the saving effected by the electric arc weld- 
ing s_\steni is being made at the rate nf approxi- 
niatel}' $200. CKX) a \ear wiili nur present equip- 
ment. This figure includes a direct sa\-ing as 
compared with other methods of about $1,%.000. 
J here is also a saving arising from the fact that 
we keep engines in service a greater portion '<i 
the time, which makes up the balance of the 
$200,000. Our figures show that we are -a\iiig 
about 1400 engine days per year. We ha\e >>]>- 
tained, in other words, service of four additional 
engines without any exj)enditure beyond that 
required to install the welding system. 



"The net returns secured on the electric weld- 
in.g investment anmunts to appr(]ximately 500% 
per year. These figures show that the installa- 
tinn (if the electric welding system on the Rock 
Island Lines has been ;i ver\' profitable invest- 
ment. 

"There is still a fotallv unexplored field in the 
maintenance of freight and passeii,ger cars, which 
pmniises to ecli]ise in im|)ortance maintenance (.if 
motive imwer. The present indications are verv 
>tron.g that when we .go fullv into the electric 
welding process in the fire box, tioiler. locomo- 
ti\'e, machinery, steel tanks, car work, track 
work, etc., we can well use 150 units and t.- ff ect 
a net saving of apiiroxim.-itely oiir luillion dollars 
a \ear. 

"We could with this equiimient in operation 
show a saving of around 7000 engine days a year 
which means that we would be able to secure 
fr(jm our jiresent engines a mileage that will 



15 



ELECTRIC ARC WELDING 




Fig. 31. ICnuiiie side rods repairetl liy ilectric an: welding. 
'riu- ends uf llusf i.'ds ueie badly wniii aii'l new m lal w.is 
buih in by the u^c "f the aie. ()ne «>f tlieni lui*; been niaeliined. 
the other shows niilv the rr)niili weld, bill so lu-ally was the 
work done th.ii it is .lllbcillt t.i tell uliieh is wlllidl. 




I-'ifi. 3J. K . ' ilrrnni repaire<i by Klectiie Are WeMiiiH. 

Tlic hole ill this liileriini was badly worn. I'.y ])IacinR a cop- 
per banri or ferrule nt the right si/e in the hole and building 
np arouii.l it the ferrule cinild be knocked out after the weld- 
ing was coni]ileted, le,-iviiig a perfectly smooth, loiilld hole, 
which needed no niachinini; , 




i'ig. .^,* .\n eccentric siieav.- repaired by electric w Iding show- 
ing how it is possible to weld both malleable and grey iron. Tlie 
key-way in the driving wheel shaft has al'O been built up and 
niilled out, sa\ing the scrapping of the entire shaft. 



eiiiial that which cmild nthL-rwise unly he si-ciircd 
1)\- the purchase of 23 additiniial engines." 

The figures on the work done on the Rock 
Island R. R. are reprmhiced mi page -3 and are 
wiirthy (if ver\- careful study. 

h.verv dav that the loconiotive is laid up in 
llie repair slmi) means a 1' iss of a large sum rif 
money for tlie road, 'i'he use of the electric arc 
has made it possihle to repair a great inimher 
of Ciises of breakage and wear w itliont disman- 
tling the locomotive, thus putting it hack into 
ser\ice witiiin a dav ny two. instead of keeping 
it in the sho]) a week or ten da\ >. 

'The impiirtiince of reclaiming hrnkeii .iiid 
worn jiarls ot rolling stock' has hecome a suh- 
ject of \ital imjiortance with the railrnads in 
ihe ]iasl few years. ( ireatei' attention iIkiii ever 
iKlore has been given lo these smaller ecmiomies 
with ,1 \iew to building u|i the earning capacit\- 
1. 1 the mail, in f;icl. the motive power depaii- 
meiit hii^ assumed a \ crv large part in putting 
the roaiN on a dixiileiicl ]ia\ing basi--. 

The chief Uses n\ (be electric arc in the rail- 
I n.'id sip ,p are : 

1. Welding fines in hack fine-sheet. 

2. r.uilding up wurn surfaces on the steel cast- 
iii.gs ■ it the locomoti\ I-. 

.V Repairing broken frames and other steel 
ca-~tin,gs. 

4. l-"ire-box welding. 

5. Rep.airing of shop tools. 

ii. Welding in side sbeets. tnhi' sheets and <!■ lor 
sheets. 

Mefal Electrode Used 

In practically all railroad wurk, the^ metiil 
eleclroile is tised. The Railwav .Mechanical 
l-.ngineer in the issue ol Xovemher. l''l(i. sa\ s : 

"The metal process usually gives a more re- 
li.ible weld, gi\es finer te.xture to the met;il. 
lea\es it less pormis, can lie more iieath' executed 
and finished, reiptires less power and may be 
easier cniitrolled. The carbon process is well 
suited for tilling holes in large castings and 
similar work, but the metal process is best for 
building u|i metal nil surfaces since the additi(.)n 
of metal is larirelv automatic and the continement 



16 



RAILROAD SHOP REPAIRS 



of tlu- lu-at avoids Hnwini; and niii-utt' tendencies; 
in "tiler wnrd^ tlie added metal stays where it 
is ]int. With suital)le control provisions it is 
])os'iilile t(i conihine methods. heatini( the work- 
uii^ zone li\ the use df the carlxjn arc. and huild- 
int; u]> the new metal with the metal electrinle, 
the procedure dependinp; upon the character of 
the work and the ahility to reach the nmlten 
condition simultaneouslv upon ohject and elec- 
trode." 

The caihon process can only he used etfec- 
tiveh where the work can he placed upri.yjht on 
a tahle and w here the castint,^ can he suhsequently 
annealed, which ])ractically eliminates its use 
from the Railroad .'-^hops. 




.35. liEFORE. i'.nikcn EiiKine l-"r.-iiiie with break cut out. 
Iii*L-[i;ii*i-il t'lir weldius. 



Rcpti inns' Brctik/i<rc 

In repairing; hroken and wurn ]iarts. the prep- 
aration consists mainlv in cleaniui;" the piece of 
all traces of oil. rust. etc.. hefore welding; is 
heijun. Where twu pieces are to he joined, tlie 
eds,'es of the sections are chipped out with .i chip- 
piniL,' Iiammer to ])rovide a "\ " shaped groove 
af tlieir junction, therehy insuring; that the joint 
is completeK- hlled with metal. W here thick 
sections arc to be joined, it is often advisable 
to provide a groove in each side, in any event 
the <;roove should extend cntireh' throuuh the 
junctiiin of the two pieces. 

In lie.t;"inninjj. the arc must reach the bottom 
of the groove. Liquefy the metal at that point 
first. Fiu" this reason, the groove between the 
piece- nnist have an angle suf^ciently large to 
allow the operator to get to the bottom. ( )n 




I"ig. .'4. Lincoln Arc Welder in Rock Islaml R. R. shops. Sil^ 
XI]., showing tile black cativas screen with which the \\ chlci 
surr.nui'l- il. thus protecting the eyes of otlier wnrknu-u 
from glare. 




rig. ,i5. .\I-TI-:K. The Comiilcte.l Wei. I. A piece of boiler 

plate is placed around III ■ bottom of the jjap as shown in the 

illustration, in order to hold the new metal in place 

ilnring welding. 



\ 

r 



N 




I'ii;. .^6. Engine l*r.'inie repaireil Iiy tlie LiiK"]ii Arc WcMei at 
the Rock Island Shops. 



17 



ELECTRIC ARC WELDING 



<^ "'^ — -— - - 






^^ >^: 


mm- ^ 



Fig. 3r. Hrri'lxl-. in, ..Inv nt tin- •iecunils art- i-hqiTK 
uitli Ilic liaiiiinct , iiKiUing n •■\"' shaped groove. 





hdik-r platfs. the angle is usually 'K) (legrees, 
while on large steel castings the angle may be 
from 45 to 60 degrees. 

(jn most work, it is necessary that the two 
pieces first be aligned, and clamped together or 
clamped to a third piece. If a (ine-sided heat 
occurs, siinie allowance must he made fur itnciptal 
contraction. This part nf the work calls for 
experienced men. If it is desired to Iniild up 
metal of any height with the carbon arc process 
a mold of asbestos, fire clay or carlxm must be 
made to retain tin- niulten material. The work 
of welding should if possible be done in one con- 
tinuous heat. One good example is given by The 
Railway Mechanical l''ngineer, drawings fvir the 
job being repruduced on page IS (Fig. 3''). 

They say regarding this job. "The frame at 
crack is first v'd out on both sides with the oxv- 
acetylenc cutting tlame. and chipjied out with an 
air hammer and chisel to get a clean surface as 
shown at A in Fig, M>. A sg-inch plate, about 
1 inch wider than the frame, is then fastened 
to the bottom, b'roni this as a basis the electric 
welder builds up the full width of the frame 
first on one side and then on the other as shcjwn 
;it I'., After the v is filled on both sides, ?s-inch 
round bars about 2 inches longer than the full 
w idth of the v are welded on the outside as rein- 
forcement, starting at the bottom and building 
u[) (see C, Fig. 39). The very fact that these 
bars are round enables the o|)erator to easilv and 
successfully weld them in bv being able to get 




■ Round Bar Beveled at £nds 



Fiy. ,^S, ,\ I,ocoiiinti\ e Sulv Ki,ime with fi\( 
in it. -V ]>alcli on the inuii rtn>: can aN 



separate welds 
t*e seen. 



I'ig, 3*^, Drawing show in^ nietliod of repairine: engine i 
iCi'iirlesy RAILIVAY M hX HAXICAL F.XGIXEER- 



18 



WELDING CRACKS AND PATCHES 



in around tlu-iii. The cnnijilctcd weld is shown 
a1 D." 

Tlie cost table on page 24 ci'nii)ile(l in one of 
the largest locomotive shops in the cnunti'w show^ 
the variety of work and the saving over a jierioil 
of seven months. The cost of electi'ic cm-rent is 
figured at 2 cents per kilowatt hour. 



Fine Jf\'ld'iiig 



^\'elding the flues and back flue-sheet, if prop- 
erly done, will enable a set of flues to go the 
three-year limit without attention in a "good 
water" district. The old practice i)f rolling a 
few leaky flues after the engine comes in from 
a run, is entirely eliminated bv welding. Weld- 
ing flues, however, will not entireh- cure the flue 
trouble, wdiich arises from bad water. 

'Ihe \\'elding Committee of the Railway Elec- 
trical Engineers' Association makes the following 
rt commendations for flue welding with the elec- 



tive arc: "Ihe ideal jirepai'.ition nt a set of Hues 
for welding is a^ fallows: 

1. Put flues in exactly as if they were not to 
be weldeil. 

2. I''ire the boiler, or, better still, send the 
engine out for a run. The object is to liurn the 
oil out friim luidei- the beads of the flues and 
allow the flues to take a permanent set. 

3. The flue shei'l shotfld then be brushed off 
with a stiff wire brush i ir sand blasted. The 
oliject is to eliminate, so far as possible, the 
scale of oxide on the tlue sheet and flues. 1 1'l n 
oxide is not a good conductor of electricit}' ;ui(i 
causes difficulties with the arc which in turn may 
pi'ijduce a pcior weld. 

The welding of 2-inch flues is done best with 
's-inch electrode. On sand lilasted flue sheets 
90 to 100 am]K'res is enough current. Mue 
sheets that have a thick coat of oxide require 
fi'oni 120 to l.'iO ;uiipei'es on this size wire. Five- 




Fig. 40. 200 .\mpere Lincoln Arc W^elder nn welded Irtick f<ir eTigine house service. 

19 



ELECTRIC ARC WELDING 







=;i. 




A> 



V\^. 4 1. Tiilif^ uclilcd into tlu- tube slu-t-t uf tile locuinotive 

hoiU-r. This is an exct-ptinnally ptuxl t-Nample of this 

kind of work. 




I'^iy i- \\'\'\ 1 -:'. ^iuctv 111 loroMiolivc tire Iiox sliouiiii; 

two iLUciu's m.uit uilli liie arc wclilf 1 . Or.liiiarily thi.s wt-M 

would Iiave bt-en made withonl dis-a^sembliiiR. but ttu- lire bo\ 

w.is l.lkin out for olluT repairs. 




inch flues slii.iuld \k wt'lded with ;fo-inch elec- 
tn.ide with 120 to 140 amperes depeiidinsj upon 
the cniidition of the flue sheet." 

The .\inerican Railway Master Mechanics' 
AsMiciatiun is ver_\ favorahiy dispi)seil toward 
the use of electric weldinjj and as lung agu as 
I'M 2, iiad red immeiided its use. l-lven at that 
time, one ruad had 2C)0 engines runnint; with 
flues welded in and it was found unnecessary to 
icmiive flues when eiiijine'^ came in fur repairs. 
It was fiiuml that maintenance cost wa> ahnnst 
entirely eliminated, enijine failures were avoided 
and engines could lie kept in service a greater 
k'ngth of time. 

.'~'ee "Sug.gestive .\pplic;itii iiis," I'age 45. 

U'cldniv Cracks diid Patches 

Tile welding of crack-- and patching nf -cams 
(.■tfer the most difficult jirohlems to the welding 
operator. Tlie .Xssociatiim of Railway i'llectrical 
Engineers otters the ftillnwing directions fcir this 
cla^s of work : ".\ crack should he located and 
a; least two inches hevmid each end a ' j-inch 
hu!e drilled. The edges of the crack shnuld then 
he heveled so that the cijieratur can get at them 
til make the weld. ( )n horizontal cracks, the 
liiwer ed.ge does n(jt need to be beveled hut -linulil 
be clii]iped ti.i give a stpiare edge. The upper 
edge should be beveled at least 45 degrees. Ver- 
tical cracks should be beveled from 30 de.grees 
t(i 45 degrees on each side. The less material 
reiiKived from the crack the better. .Ml welds 
>honld be made with the least possible amount 
111 metal between the edges of the original ma- 
terial. 




1 i;^. 43. l'ro\idnig for exfiansiou in side sheets b.v making the 
Weill in the alternate •.ection-. 



1-^ig. 44, Leaky Knel> in iiuid ring rrii.iired by biill.iintj up !»ad 
aiound tile head of the rivets as showti. 



3) 



iiii liiiDiiiiiiiiiiiiiiiiiiiiiiDKiiii iiiiiniriini 



STANDARD RAILROAD PRACTICE 



"If the crack or seam is a Ions; one. the metal 
should be put in aUernate sections 4 inclies to 
6 inches long. The operator should put one 
layer of metal in each of these alternate sections 
starting near the center of the seam or crack. 
The open sections can then be tilled, starting at 
the coolest point. Successive layers of metal 
can then be applied until the seam is c<impleted. 
\\']ierever possible, at least 30 ]ier cent of rein- 
f(.ircing shoukl be applied so that the cross-sec- 
tion through tile weld is .W ]ier cent greater than 
the section of the original ])late. After each 
laver of metal is welded into the seam, it shmi'd 
be thoroughh' bmislu-d with a stiff wire brush t" 
remove as much of the oxide as possible. \\'here 
the sand blast is available and can be used on 
the job the results will justify the ex|)enditure of 
time necessary to clean the metal between layers. 
The same general care should be taken in the 
welding of locomotive frames as in the case of 
the boiler plate of the fire box. 

"Aside from the use of judgment in the appli- 
cation of the electric arc welding pr(icess, there 
are three rules which the (iperat(ir nuist ohserxe 
to get the best results in welding; 1. Hold a 
short arc. 2. L'se a low current. .S. Alwa\s 
work on clean metal." 

Provision for Exp{i/isio/i 

"\\ here long seams are to be welded, as for 
example, in welding in a half side sheet, prac- 
tice again differs as to the best method of tak- 
ing care of expansion. Some operators prefer 



r >^/* 



«i 





i *»»n» 



I'ig. 46. Worn Engine Cross head repaired l)y welding on piece 
of boiler plate at the top and welding crack as shown. 




I'lg. 47. Arc WildniK as used in making smoke 
locomotive boiler. 



bi'x for 




Fig. 45. A patch built up around a locomotive mud ring. This 
patch is nearly 8 feet long and made a saving in cost of over 
$2,000. besides the saving of a month's delay in mak- 
ing the repair. 



\\ oui Siccl ^ a-.ting — t.ncninnti\e Tan — re 
building up worn surface by arc welding. 



21 



ELECTRIC ARC WELDING 




® 
® 




/ 



® 



/ 




I'ig. 50. The prompt repair of broken shop tools is often of 
t:reat importance in the railroad repair shop. (1) A broken air 
drill socket for 1" diameter drill. A new socket wonid have 
cost $1.80, besides delaying an important repair job. (2) The 
same drill socket repaired by the Lincoln .\rc Welder. Cost of 
repair. inc]iidin,2 preparation of weld,, was IJ cents, (i) Broken 
pipe wrench for 3" pipe, repaired by the Lincoln .-Xrc Welder. 
.\ new wrench wonld have cost about $6.00. The repair co-^t 
2)1 cents, inchiding preitaration. weldinii and grinding off super- 
fluous metal at weld. 



til allow for expansion by wiileniiig; the gap be- 
iween ilie sheet, this being done by setting the 
iK-\v sheet a\\;iv at a slight angle; the allowanee 
u~nally niaile by these operators is about 's-inch 
lo ' 4 -inch [ler foot of length. Then when the 
weld i-' begun at one end and the work is carried 
uu. thr twii edges will gradually draw together, 
due til the contraction in the weld at cooling. 
• Ulier iiperators prefer to ]ilace the two edges 
in lm;tl relation to each other, holding them at 
llie proper distance aiiari liy means of 'tacks' at 
intervals of 12 inches to IS inclus. The weld 
i> llien iii'giin al eillier end and as it appro.aches 
a 'lack' the lack itself is cut out by use of a 
chisel and solid nielal welded in, the tack siniply 
■~rr\ing llie purpose of holding the --heels in 
proper relation unlil the weld is made. When 
tacking is used, it has often been found .advisable 
to w idd a short space, s.iv six or eight inches 
from one end to the se.am. then go to the other 
end of the se.im and weld a like distance, thus 
kee]iing healing and e.\]i.insion .at a niinimnm." 

Stcuiddrd U'cldiii^r Practice 

The .\ss()ciatioii ot l\ail\\a\ h.lectrical h.ngi- 
neers has i-ecoinmeiided the fodow ing with refer- 
ence to siaiidardi/atiou and shop organization 
li.isfd njion the experience of their \,irious mem- 
bers on dilterent ro.ads. 

■■'rile import.ance of the weldin.g ojierations in 
a lociimotixe sho]) or engine house is so great 
that it IS necessary for the work to be di>ne under 
the direction of a competent and res|ionsible 
member of the railroa<l organization. A very 
successful solution to this problem has been mafle 
on several systems by the a[i|)ointnient of a 
Su]iervisor of h'lectric Welding who is r(.-s[)on- 
silile directly to the general superintendent of 
motive power. The Supervisor of Electric \\''eld- 
iiig makes the practice of the several shops uni- 
form so that the failure of one shop to ,get results 
from a process can be traced to its origin. The 
Supervisor of Electric \\ elding must find a suc- 
cessful way of doing each job and require every 
shop to perform the operation according to his 
instructions. 

"Oi)erators are obtained in most cases from a 
shop organization, f )n roads where an appren- 
ticeship training is provided most of the opera- 



27 



1 1 nraniiji'iifflirpiiiiini iiii 



STANDARD RAILROAD PRACniCE 



raw]u]flinjiijjJM 9 mm 




Iml'. -1. Linc.'i'.i .\n- 'v\ii.i-i 1 I'lul.ibii- Imh-i uitiitjru.i, huii-- 
ing as used in engine hnuse on Kaslern Uailroad. The canvas 
kepps >iut the du-^t :ind dirt prevalent around the cnfiinc house. 

tiTs are men who have just c 'ni]ik-tc<l the appren- 
tice work. Ft is desirable to have operators who 
liave liad general experience in a railroad shop. 
Ir. simps which have a local electrician the care 
(it the electric arc weldinq- ei|uipment is handled 
li\ the chief electrician. In engine houses the 
operator of the e(|uipnient is usually trained to 
give the equipment whatever care is necessarx'. ' 

St(})idardrz(}ti(iii of Opcnitions 

The tendency at the jiresent time is to stand- 
;n'dize the welding tiperations in the same manner 
iliat the machine shop and other operations have 
been standardized. Where welding opieratidus 
are thoroughly standardized the wi.irk can be paid 
for (in a piece work basis. The standardization 
of welding operations is comparatively simple on 
systems which emplov a Supervisor of Electric 
\\'elding. ( )n other roads it is more difficult to 
standardize the operations, but the necessity for 
having them standardized is greater. Ninetv- 
live per cent of the electric arc welding done in 
railroad shops is on operations which can be 
standardized. The following factors should be 
determined for each job of this nature : 1 — Size 
of electrode. 2 — Kiml of electrode. .i — Current 
in the arc, and 4 — Time required for the opera- 
tii.n. 



Eqiilp))ie/it 



A thorough discussion of the equipment avail- 
able for electric welding in railroad shops will 
lie fiiund on pages 4f> to 56. 




oin Alt W.lder I .>l.il i. in.ci > 'I'mr-) iu^ta 
engine lion^e on large railroa<l. 




Fig. .S3. Engine frame prepared for welding. 




Fig. 54. Fngine frame after wehiing. 



23 



ELECTRIC ARC WELDING 



MlSCELLANtdVIS El.KlTkU \\ KLHL N 1,—LocO -MOTIVE SlIOI'— X.V.ME WlTHHEI-t OnE MoNTH 

Xo. of 

Operation 

Biuii|i(_r Hiam 1 

Brake Shoe Heads 102 

lirake Hanger Bracket 1 

Crossheads — Pistim 17 

C'rossheads — \'alvc -- 

Crossliead Pins 3 

Deck Castings " 

Dri\ ing Boxes -4 

Driving Box Lngs 10 

I'Vames 2 

Frame Cross Brace 1 

Kccentric Blades 5 

Eccentric Crank 1 

Gnide Bars 69 

Cuiile Viike 1 

Levers — Ci.iinliinati' Ml IT 

Links 33 

Link Hangers 1- 

l.ink Saddles 2 

Miscellanetins 

Quadrants — Teeth 3 

Rods — Main '' 

Rods— Side— Grease Ping Holes 100 

Rods — Side — Spade Pin Holes 1 

Rod Straps 7 

l\'e\erse Lever Heels 3 

Reverse Lever Latches 

Spring Saddles S 

Spi.ikes — Driving Wheel 9 

Shnp Tools and Machinery 2 

Tail Sheet 1 

Tumhling Shaft - 

Tender Truck Eipializcrs 8 

Transmission Hangers 6 

'Idtal -187 $■228.22 $00.62 $175.?2 $4tiAJh $1,839.54 $1,375.18 

Xet saving lor nmnth . .$1,375.18 

Misi I i.i,.\NKi>rs .Ions 

No. of Other .'^a^ing]ler 

1916 operations Lahor Material Current Total cost method Saving oiK-ration 

Jaraiary 461 $183.07 S47.88 $155.70 $386.65 $1,176.58 $ 789.93 ^^1.71 

February 433 21S.08 59.89 187.70 4<)5.o7 1.558.56 1.092.89 2.^2 

.March.' 5S4 253.37 M.57 199.13 517.97 1.871.44 1.354.37 2J2 

\l„,l 325 172.92 42.62 134.20 349.74 1,232.<,5 882.91 2 72 

>;a\ 487 22i<.22 60.62 175.52 4()4.36 1,839.54 1.375.18 2.c<2 

h.ne 579 210.09 54,94 175.52 44<t.55 1,726.10 1,285,55 2.22 

July ':'2,'i 165.97 41.12 135.62 342.71 1,501,33 1,158,62 2,22 

ToT.VLS 3,392 $1,431.72 $371.(4 $1,163.39 $2,966.75 $10,006.20 $7,939.45 $2..^4 

T.\r.i.E I — St.\temext oi Wcirk Performed with Electru' W'eliiek .\t Locomotive Shops. 

.\ctual TMlal Time Cost 

Nr). uf time eosl. rueparing preparinjj Total .Average 

No. of lilies welilins aelual for weldins for coM to oi.^t per 

2916 eiigiiu's welded lir, and mm. Ealior Mal<-iiai Current weldint; lir. and niin, welding engines eng-ne 

Total fur 2- 111, flues 247 4J.h40 .\Riri5" $wa.77 $1N1,0'I $84,1.7: $:.015.5S 22_" 45" $80,39 $2,093,97 $8.48 

Total for 5- in, flues ly(> 5. 034 1,47J'45" .^20 01 8.V47 442,16 1.047,64 24' 00" 10,08 1,056,12 5, .19 

Total for smoke consumer 

,j,l,j.5 2A4 1,046 122'00" 42 83 9.76 36.60 8'f.21 89.21 .37 

24 











Other 




Lalior 


Material 


Current 


Total cost 


Methoil 


Saving 


$ 1.41 


$ 0.33 


$ 1.35 


$ 3.09 


$ 5.00 


S 1.91 


11.79 


2.48 


9.55 


23.82 


80.58 


5o.76 


.33 


.02 


.08 


.43 


1.25 


.82 


12.96 


3.29 


10.53 


20.78 


133.06 


1(10.28 


2,39 


55 


1.95 


4.89 


13.^3 


9.09 


.83 


.18 


53 


1.54 


4.47 


29,3 


30.23 


6.90 


20.70 


57.83 


484.32 


420.49 


2.10 


4.20 


1.8') 


8.10 


105.48 


''7.,i8 


1 .1 18 


.33 


.88 


2.29 


6.90 


4.61 


5.11 


1.25 


4.20 


10.56 


57.84 


47.28 


2.59 


.60 


1.80 


4.99 


21.75 


16.7o 


.% 


.21 


.80 


2.03 


5.44 


3.41 


,19 


.05 


.15 


.39 


12.74 


12.35 


99.52 


28.91 


86.33 


214.76 


423.03 


208.27 


.66 


.W 


.30 


l.(>(. 


9.74 


8.68 


2.66 


.60 


1.73 


4.99 


32.37 


27.38 


3.44 


.89 


2.35 


6.68 


36.41 


3J.73 


1.36 


.30 


.<X.I 


2.56 


3.24 


.08 


.59 


.10 


.45 


1.14 


8.32 


7.18 


1.4S 


.19 


.50 


2.17 


4.86 


2.09 


.28 


.05 


.2:-, 


.56 


2.43 


1.87 


2.48 


.75 


2.18 


5.41 


9/W 


4.58 


20.61 


2.70 


10.03 


.53.34 


89.04 


55.70 


.05 


.2^ 


.68 


1.56 


12.29 


10.73 


4,16 


1.10 


3.30 


8.56 


53.78 


45.22 


.?7 


.15 


.45 


1.17 


7.80 


o.o3 


.06 


.13 


.5.1 


1.32 


11.55 


10,23 


2.19 


.<)ii 


1.80 


4.59 


22.99 


18.40 


0.01 


1.50 


4,20 


11.71 


42.50 


,il).79 


.72 


.13 


.50 


1.35 


6.01) 


4.05 


.•■3 


.05 


.15 


.53 


1.50 


.97 


3.13 


.85 


1.0(1 


4.98 


49.21 


44,23 


4.18 


.80 


3.15 


8.13 


78.39 


71 1, 1 7 


.57 


.10 


.3,S 


1.05 


1.38 


,33 



COSTS AND SAVINGS 



imimiiMiItilllliliin ..MiiMtuniimmmi 



T.\I!I.K 



-CdMl'AKISIlX OK ElHCTRIC 



Wkmung vs. Old AIi.thohs .\nd (Ias Wki dknc M.mik (i.\ Km k 1.-i..\.mi Line 



l)e-,cn|iU> 



of 



parts 



Ct>st (.1,1 
nu-thKrl 



$ 16.28 

\ alve stems ^ 17 95 

Eccentric str.ips I ' -^^^ 

Cylinder cocks 3,S6 40 

Cioss heads 47 91 

I'iston lieads j.'^") 

Motion saddles gt,' ^^^ 

Trame braces 1881 

Crank amis ^■^,, 

Rocker box castings ,-^U 

Transmission bar 7' i- 

Reach rod ^f^'~ - 

Rocker arms 7 70 

Kng. truck equalizers 1t70 

Truck frame ijg 

Trailer jaws • ■ ■ ■ ; ' • • • ;-„| 

Extension piston cross head j ^^ 

Brake beams ^^"jq 

Brake hangers y -g 

Smoke arch brace ,■-,, 

.\ir pump valves 1~ 45 

l.ugs on valve yoke " ,1 , 

I'lisli car wheels I 1^ 

Stilsoii wrench ^ - ijn 

Urill chuck V52 

I )river brake fulcrum ^ 176 SO 

\Mieel spokes " I -''j^^ 

Main rod blocks '() 00 

Triple valve gage 72.24 

Link blocks '■V9S 

Lift shafts "74.! 

Quadrant 55 114 

Wedges ^- ,1, 

Lhafing castings 349 69 

Plugging and building up holes y-,^ 

Tire rim keys j'^j", 

Throttle stem 2 5s 

Reverse lever support hK3S 

Smoke box P 5 1 

Hub liners " ' 15 V 

Strip on cross heads "l 75 

Fire door handle 6,5 ""l 

Boiler casings 4 qH 

Frame buckle 1^ '25 

Trailer yokes Via 

Motion frame y ^-^^ 

Combination lever ^-"^ 

Lugs on trailer hub "f, SI 

Center castings ' 1 'i 5 

Spring blocks - j_, 

Guide blocks S \~^ 

Binder ^ 7'-> 

Steam pipes 99 86 

Flat spots on tires 55 65 

Cylinder bushings '>i\ 4^ 

Building up siile rods |- _;, 

Grease cups ... ■_ ■ g „„ 

Stationary fire door •"' ^71,/) 

Cracks in tanks 140 52 

Tetticoat pipes 2 677 80 

Filling worn spots ■ • ■ " 7n\;6 

}''"5 . ■ • '.'.'.'.'.'.'.'.'..' 105JI2 

Reverse le\ er parts 

r ,,1 !.'.'$6.4,!4.10 

iutal 



t ost i;.is 
weldini; 

$15.21. 

7.6.5 

1.04 

120.2.i 

32.74 

10. "4 

4S,00 

26.14 

4.3s 

1 .09 

13,24 

17.24 

13 04 

4.3s 

4..50 

2.1s 

7.45 

6.25 

1,33 

21. SO 

111 -I, 

1,00 



113 IIS 
2S,34 
3,27 
51,4') 
4 1.2 
11, ir. 
(,o h'l 
10.70 
2S0.'J4 
5.3S 
l.OH 
4,36 
32 43 
13,11 
31 on 
LO'i 
30,30 
2.41 
I., 45 
10,17 
1,75 
4,52 
2S,56 
1 ,01"' 
4.2'' 
13.10 
5.12 
95.77 
9.40 
SI, 16 
11 45 
8.72 
113 62 
52.37 
1.064.60 
87.23 
74.04 



5.74 



w.l.liuK 

$ 4.76 

2,3 s 

.34 

37.73 

10.24 

3,44 

15,00 

S,I4 

2 04 

1,3S 

,34 

4 24 

5,24 

4 04 

1.36 

1,36 

,68 

3.40 

2.14 

.53 

6.80 

3,05 

.34 



35 08 
I, ,84 

1 02 
I 5 4H 

1.02 

5.59 

21.69 

3. 20 

1411.47 

2 3S 
.34 

1.36 
■ I (13 
4.11 
12 66 

.34 
9 iJ 

,91 
1,95 
4,17 

1,52 
9.0(1 
.34 
1,29 
4,10 
2,12 

2^.77 
3.40 

31.16 
3-93 

3f. K. 
lh.37 
32u.6lt 
27 23 
23.04 

S<'21,61 



over (.1(1 
nicthod 

$11,52 

15,57 

1.112 

318,67 

37,69 

4,88 

84,50 

10. (>7 

1.42 

.91 

li. 51 

2,40 

11.01. 

1.411 
4. "4 
1,01 
1.70 
1.36 
1.97 
25.65 
2.94 
1 ,26 
14,32 
2 811 
1,241.72 
7.04 
18.98 
56.75 
22.96 
,5.84 
33.35 
5,10 
20" 22 
.84 
1.16 
2.02 
51.45 
8.40 
12.66 
1.41 
53.89 
3.99 
3.30 
4.93 
.48 
2.98 
67.75 
.81 
4.23 
l.ii'i 
1,07 
70.09 
32.25 
62.32 
7.86 
5.28 
337.53 
124.15 
2.348.20 
43.43 
74, ^'8 

$5,512.4'! 



Saving N"o. 
over gas engs. 

$10. 5i' 6 

5.25 2 

.7" 1 

82 50 13 

4 



22.31, 

33.111 
18.00 

3.111 

.75 

9. on 



18.34 



10 
5 



3,02 


1 


3.01. 


1 


4 05 


3 


4,1 1 


I 


8n 


1 


15.11. 


o 


7,5(j 


4 
1 


l,5i 
6.0( 


1 
1 


78.0' 


15 


19.5' 


9 


36.00 


20 


3,00 


1 


7,5" 


3 


48.0IJ 


2 5 


7 ^1. 


1 


140.4; 


70 


3.0" 


2 



j; 




20.92 




1.50 




4.5(1 




6.011 




3. on 




19 50 




7c; 




3.00 




9 On 




3.01. 




66.011 




6-00 




50. on 




7.5n 




6.00 




78.4i> 


14 


36.01) 


18 


735.00 


12K 


60,0ij 
51 .In 


38 



$1,834 1,- 



X^BIf- II.— CoMl'.'VRISnX OF ELEfTRir W'eLDI.VG VS. OTHER 

Mkthulis. 

Cost of 

Description of parts other l ost nf .No. 

methods, elec- weld. Savings engs. 

Pedestals $ "5.00 $ 45.24 $ 599.76 5 

Tank frames ^W -36 ,6 1 

Shop tools «.36 . ^_ ,;5 

Piston rods '»64 10.0 

ili^^nlt dr. axles 121.50 4,90 1,6,60 

l;;^!,i^^p'^*ax?;::::: ^^ 2: 289.6 

Rushing st^ybol. holes.... ,294.9 ..M .2- ^.6 

Frame"* ; ! 1 1 1 'w LOO 133.28 797.72 11 

C^aci^in-fi^e'box^s 2.431.27 297.17 2.134.10 92 

•J-,,,.,! $7,839,15 $1,154-42 Jh. 684-73 

2S 



C.-c^t 
of other 
methods 

6.434-10 
7.839.15 



T-\Bi.F. III.— Sum M 

C'n.vf iinJ Sa-.-nigs -f.-r 



Co-t (.f 
Jas welils 



3.697.42" 



$ 6.45 



Cost 

f electric 
welds 
921-61 

1.154-42 

2.075.03 



,\RV. 

Savings 
ov^r otlier 
methods 
$ 5.512.49 
6.684.73 

$ 12.197.22 $ 4,377.13 




Co^ts (I'n/ ,S\i:in£,^ —/''■'' 1 (■( 



$ 77.209.20 
94.069.80 


$33,068.84 
44.369.04' 


$171,279.00 


$77,437.88 


'Figures 
u elded witi 


sIk.W cost 

1 gas. 



$11,059.32 
13.853.04 

$24,912.36 
if gas weld if 



t.6. 149.88 
80,216.76 



;146. 366.64 
work colli. 



$22.1109.56 
30.516.00* 



1 have he-.Il 



ELECTRIC ARC WELDING 



Ship Building and Repairing 




Tii: ?-. I-;K(.lric arc welding outfit niountcii on nmttT iruck. Tlii'; mittit is the property of The T'ootn Pioiler & Wi-liliiig Co., 
nf\ eliiiul. (Hiio. and i^ here s"eii doing repair work on t!ie "Seeaiidhec." the largest jiasst-nger steamer on the Great Lakes. The e<niip- 
inent consi^tv ot" a .VS H. i*. Novo Engine belt ei-nncL-ted to a 1.^0 ampeie Lincoln .\rc \Vel<l<-r. The engine also operates an air 
conii'ies.,i.r fin .-[derating a pneumatic hanim-.r. The cable which carries the welding current can l»c seen entering the sllip thr(.'Ugli the 

opening in the side. 



tlciM-ly alliid til il> um.- in i-;iilr(i,Til vhu])-^ is 
the use of arc wcliliiiy; in sliipliuililiiii,' and re- 
|iairs. 

Here attain tremendous developinenls have 
taken place in the vear since the I'liited .'States 
entered tlie war. \'ery wide use is now being 
made oi electric welding in the actual cf instruc- 
tion oi ships, where it not only costs less than 
riveting, hut makes a very vital saving in time. 
In fortunately ceiisorshi]) rules did not permit 
the photngraphing of this work or the giving of 
detaileti information concerning it. Shipbuilders 
who are interested, however, can obtain all the 
data, ami the wonderful possibilities of this 
process in ship building will be substantiated by 
any one wlni takes the pains to thoroiighlv in- 
vestigate it. 

At the present time the insurance rules do nut 
jiermit the weliling of any strength meiubers on 
the vessel, that is. the welding of plates or ribs, 
or the welding of the plates to the ribs. 



Regarding this use uf electric welding, j.inies 
( i. 1 )iidle)'. Research Engineer, has the following 
til saw in a recent issue of International Marine 
I'.ngineering ; "I-'ur mure than five years past, 
lailways of the L'nited States have been employ- 
ing metallic electrode welding in largely increas- 
ing amiiunts and with astonishing technical and 
(Cdnomic gains in securing practically leakless 
ciinditiiins of tubes ami furnace sheets of the 
liicnnic itive boilers. 

"Jdie technical literature of railways and weld- 
ing demonstrates beyond successful controver- 
sion that jointures of more than 100 per cent 
efficiency can be readily and commercially secured 
by electric welding means. Even the truly re- 
markal)le results secured under the inmishing 
ciimliiions of steam locomotive service have not 
as yet overcome the friction ami inertia of 
'standard practice' in so far as the design and 
fabrication of a comjilete loconiotiv^ is con- 
cerned, but eventually the insurance and insjiec- 
tidii interests must voluntarily 'approve' or be 
compelled by the march of events to 'permit' 
the fullest possible use of electric welding in this 
tield of transportatiijii. 



26 



SHIP BUILDING AND REPAIRING 



"Passing tu marine practice, il is more or less 
common kn<:)\vledge in marine circles that elec- 
tric welding has been successfully and economi- 
cally employed for many years past in many ports 
of many countries in repairing of parts of ships, 
which otherwise must have been tied up for 
costly periods." 

At present the rules permit the weliling of the 
following parts, and these after all are of very 
great importance because they are the jiarts on 
which riveting takes the most time and on which 
the greatest saving can he made : 

The classification societies have so far con- 
sidered and api)roved the application of electric 
welding to the following jiarts of vessels: 

Deck Rail Stanchiuns tu plating. 

Clips for Detachable Rail Stanchions. 

Continuous Railing Rods (.Joints). 

.•\ttaching Deck Collars ( L. Rin.gs ) around \entilators. 

Attaching Deck Collars ( L. Rin.ys) smoke stack. 

-Attaching Cape Rings, Smoke Stack Pipes, etc. 

Attaching Galley Fi.xtures to I'Uiting, 

Attaching Bath and other Fixtures in officers' quarters. 

Attaching Cowl Supporting Rings to Ventilators. 

Bulwark Top Splicing and End Fitting. 

Sk\lights over Galle.v. 

(a) Engine Room Stairs and Gratings. 

(b) Boiler Room Stairs and Gr;itings. 

Attaching (A) and (B) to Plating Grab Ro<ls on 

Casing. 
All Stairs and Laililers including Rail .\ttachmeuts. 
Door F'rames to Casing. Hinges. Catches Hold Coach- 
hooks, etc. 
Clips for attaching Interim ir Wond hinish to Casing. 
Entire Screen Bhd. 
Coal Chutes. 
Butts of W. T. and O. T. Bnundary Bars on Bhds. or 

floors in double bottom. 
\'entilator Cowls. 
Stacks and Uptakes. 
Bulkheads (that are not structural parts of the 

partition bulkheads in accommodations. 
IVaming and Sup|)orts for Engine and B. 

Flooring or Gratin.gs. 
Cargo Batten Cleats. 
Tanks (that are not structural parts). 
Shaft .•\lley Esca])es. 

Steel Skylights over accommodation spaces. 
Engine Room Skylights. 

Gral) Rods on exterior and interior of Deck . . 
Deck Houses not covering unjirotected openings through 

weather decks. 
Reinforcing and protecting angles round manholes, 
loiuts of W. T. .\ngle Collars at frames in wav of 

W. T. Flats. 
C)ther parts of a vessel in which electric welding is 

proposed must be submitted for consideration. 
Mtirch ..'.i. IQIS. l.l'iyd's h'cgisirr of Shipl'ing. 

;; lUith-rx PhiiC. X. Y. C. 



,iler 



-hip). 
Room 



louses. 




Xy/ 



I'ig. .^6. Tile sketches sllow pieces wliicll can he m.lde wicil the 
electric arc in silip yards. No. 1 is a very difficult and expen- 
sive job for tlie angle smitli. hut can he made for a few cents 
with the electric arc welder. No. 2 is a boat davit made tr<>ni 
an 8 inch I beam sjtlit and rewelded. The cost of this from the 
angle smith wuidd he $6.00 or $7.00. wdiereas it can be electric 
welded for $1.00. 




l"iS. ?7 . Wehiinii a hatch cuvcr on ;i stet 1 \esscl. 




Fig. 58- Hatch cover completely welded. 



27 



ELECTRIC ARC WELDING 




Fii;, 59. M.idel of Electric WcMl-.I Keel for steel 'hip. 

I I-!:.- -:. 5S and 59 are reproduced from ItitfinatioiHil Murine 

F.ttgnii't'rnig. ) 




"'.\. !'"resh water tatik> f.-r ste.Tii 

Arc Welder. Sjieed of welding 

alioiil JI1 f^ct per lii.iir 



ed u,lll 
t.iiiks w 




LincnlTi \ 
used fi'r 



Welder installe.I at H.ir Island -liiio 
erliea.l .ami vertical welding. 



It is tile npiniiiii of ex]ierts (in tlie "I'.Iectric 
Welding L'unimitlee (it the i'jiK-rt^ency Fleet 
C'(ir|i(iration." tliiit funr welded ships can lie built 
fur tile cost (if three riveted ships and the welded 
ship will re([uire alidiit half the time f(ir com- 
plete fabrication. 

The British Admiralty laiincluil a channel 
barsje of some 2CXJ ttms dea(lweii;ht built cum- 
pletelv by the electric weldini;' process. 

I'lans have been made f(ir a 75nO tmis elec- 
tiicallv welded merchant ship of standard con- 
structidii which wniM make use of the steels 
alreadx (in order and wduld be built in a vard 
designed especialb tiH" ihe constructiim ot elec- 
IricalK welded slii|is. 

It is estimated that (HI ci iiilinui nis wtdding — 
side and down weldint;. an a\'erayc speed nt 4 
leet ]ier hdiir cdihl be maintained and that (Hi 
(ixerhead or intermittent wt-ldiiit;' a speed tif 2 
leet per llnur could be avcraiicd. 

To give an idea of the Wdi'k iiuoKed. a ship 
(if lliis character would re(Hiire the e(pii\aleiit 
(if about ISd.Udd lineal feet of welding in half 
iiiidi plate. aiKl the mniiber of rivets to be dri\en 
in the yards and on the ways would lie reduced 
to about 17.0(X). This is an extreniclv important 
(le\-elo|iiiK'nt in view of the difticultx' of obtaining 
ri\eters and the iimisuallv hi.gh wages jiaid tor 
this class of w(irk. 1 )ue to the saxdng in steel 
weight resulting from a re-distribution of mate- 
rial and a substitutitm of welding for riveting 
joints, it is estimated that a welded vessel would 
have M)() tons more cargo capacity than a rivet(.-(l 
.ship of the same dimensions. 

Accordin.g to the best a\ailable informatiiui 
the cost of welding on such a ship would be 
about $41.00 [ler ton of steel, b'iguring the high- 
est ])()ssible prices for labor, material, etc., and 
that this figure might fairly be expecterl to be 
reduced to $2'^!. 50 per ton. adiled to this wouM 
be the cost of shop preparation for welding, 
erecting and fitting the plates in place, which 
would give a total cost of $('^7.00 per ton ( not in- 
cluding steel I, at a maximum, with a fair chance 
of an average cost as kiw as $75.50 per ton. 

Inasmuch as there are only Z^Oi) ttms of steel 
in the welded ship as compared with 2i«X) tons 
for the riveted ship, the total cost of all work 



28 



SHIP BUILDING AND REPAIRING 



sIkiuM 1)c ciinsidert-i! in m.ikint^ (.uniiiarisons and 
IT 'I tile cost ])t.'r ton. 

A recent issne of the Weldini; luiejineer con- 
lain^ some valualile su.uisestions lor arc weldini;' 
nn shi|i buildini;' \\<irk. l'",s]>ecial mention is made 
of tile fact that steel foundries are now workin;^- 
at full capacity and that the time consumed in 
sendins,' liack defective castint;s tn them is wasted, 
h-lectric weldiiii,' e<|uipment for immediate repair 
of these castins^s should he installed in the shi]) 
\ards and the trans|)ortatioii CMiiserveil. 

.\ nuniher of pieces which can he welded to 
.i;oo 1 advantage are shown in tlie sketch here- 
with. re])roduced by the courtes\' of the Welding 
h.ngiiieer. All of these pieces can he welded and 
are being welded in some \ards. .Such welds are 
perfectly reliable. iiriivi<ling the operator is care- 
ful and goiid m.aterial is u-~ed, precautions which 
inu<t be observed on aii\' kind nf mechanical 
\\drk. The metal electrode is the only suitable 
methofl f(ir welds of this character. Two hun- 
dred ami)eres ]ier operator shou'd be installed. 

Repairs 

1 he most important work done 1)\' the arc 
Welding process nn board ships is in the rejiair 
of the ship's Iioiler. ( )w ing to the strain which 
is bn night to bear upon the shell and lire box 
ot the liriiler, due tn the heaving, niUing and 
pitching of the shiji, there is a greater tendenc\- 
for the riveted joint.s and stay bolts to leak than 
in the case of a stationary boiler. .\lso. as a 
general jM'oposition marine boilers woik harder 
for their nominal rating than stationary boilers. 
'1 his means greater corrosion and more rapid 
deterioration. 

In general, the two classes of rlefects which 
occur are cracks in the furnace and Ieak> in the 
riveted seams and stay bolts. The L'nited .States 
gM\erniuent has \ery strict rules regarding the 
applicatinn of the pince^^ to the welding nf 
ni.arine bnilers. bm the defects just named can 
be re]jaired by the arc welding process. Tn the 
La^e ipf a ri\-eted seam which leaks due to tin? 
fact that the caulked edge has worked awav from 
the plate a reinforcing strip is usualK ptU on 
the ^eani, extending from the extreme edge of 
the caulked edge to a point beyond the heads of 
the rivets. This will ef^'ectively stop all leaks 




l-iK ()(l. lvc[Mii 'luu. Curie .\. Kycisoii. priipfilv i.t A. I*. 
Milclull ^: Sciii, ( liic'.'igo. This tilg'c.-inics .1 Jim anlpfre l.iii- 
t"lTi .\rc Wflilitifi mnlit in the small huu^c on the deck. This 
Welthn is driven h\ a Novo Oasfdine Kn^ine and tiy actual 
test it ]ieifornie(l the same amount of work on 6 galhins of 
gasoline as a constant voltage type of welder owned hy the 
same Cfnnpany. driven by a steam turbine .'ind consuming J 
tons of coal. (See page 48 for il'-seriplion of C'oListanl and 
\arial>le X'.iltaKv Wehlers.) 



r 




1 



J 



In eak lir.s h.-eii chippfl out to a "\"" shape f'.ir 




^*3^fi££.^aB£^:oaiafi^J 



-■' - - ( \iiniis {sec FiK. 611, The \vel<i 

uitli a Liiuitlii Aic \Ve]'Lr ami was praclicillx' com- 
pleled when thi^i photngrnpli was taken. 



29 



ELECTRIC ARC WELDING 



either around tlie rivets or at the caulking edge. 
Where the edge lieyond the hne of rivets has 
lieen eaten a\va\- by the corrochng action of leak- 
ing steam a whole new edge is built up. all work 
being done by the metal electrode process. 

Leaky stay brilts are repaired by reinforcing 
and welding clear over the top of the stay bolts. 
( racks in the fire bo.x are first located and holes 
drilled in the shell at each end of the crack to be 
sure that the end of the crack has been reached. 
Then the intermediate space is chi|)ped out giv- 
iiig two bevelefl edges. 

Tlie electric arc pr(ice>s is u^ed almost ex- 
clusively for this work, for the reason that it 
i< almost imj)ossible to do the work with the 
oxy-acetylene. and a good many United States 
("lovernment steambdat inspectors refuse to pass 
tile wnrk of the "xy-acetylene operator for this 
]iurpose. The tr(julile arises from the wide ilis- 
Iribution of the heat of the oxy-acetylene flame 
which causes contraction diiTiculties in the plate 
of the boiler, .\nother serious defect of the ox\-- 
acetylene process is that it is almost impossible 
to weld overhead with the use of the gas flame. 
.About one o])erator out of fifty c;m do success- 
tul Work in the overhead position. .Since a large 
]iart of the boiler work encoimtered in marine 
jiractice is overhead, this ]iractically eliminates 
the oxy-acetylene process. The fire rules pro- 
hibit its use in most instances. 

A great deal of welding is done on the decks 
anil deck houses of lioats- .Most of this work 
at the preseiU time is in the nature of repair 
work rather than new construction. On board 
the ships of the ( ireat Lakes a great deal of 
welding is done about the hatches which become 
damaged from loading and unloading. Miscel- 
laneous small jobs are done about a boat when it 
is laid up for repairs, which mean a great saving 
of time and money. While at the present time 
there is very little welding done on the outer 
shell of the hull there is considerable work being 
done about the engine room, and on the arche.s 
and tank tops. One of the latter a])plications is 
in burning ofl^ rivets where certain plates are to 
be taken (iff and new plates jiut on. Where a 
rivet is to be driven it is necessary to get one 
head of the rivet off before it can be taken out. 
Piurning off the head of the rivet and then driv- 
ing it through is the quickest way devised up to 
the present time for doing this job. Another 
a])jilication of arc welding when the boat is in 
drydock is the rejwiring of what is known as 
the rudder shoe. This is the heavy steel casting 



which extends from the stern end of the keel 
of the ship to support the rudder post. It is 
a rather frequent occurrence for this shoe to be- 
come broken and it is necessary to drydock the 
ship in order to rei)air it. This job was formerly 
done with the thermit process, but has been ilone 
successfully a number (jf times with the carlxjn 
arc process. The rudder frame is usually a steel 
casting with boiler plate riveted on it. In col- 
lisions and wrecks the rudder frequently suft'ers 
and repairs are made using the arc welding 
])rocess. 

W bile a great many applications of the arc 
welding process have been made up to the j^rcs- 
ent time in shipbuilding and repair practice, theie 
is no doubt but that (jnly a few of the possible 
.applications ha\"e been made. 

Jl.qii/pn/eiit 

V'\) to the present time the eiiuipnieiu Used 
for arc welding purposes in marine practice has 
been of three types. The engine driven unit, 
direct connected to a reciprocating engine ; the 
belt driven engine type unit, and the turbine 
driven engine ty|ie unit. The equipment is usually 
niounled on a boat which is self-])ropelIed by its 
own steam engine. The boat must carry a 
licensed engineer in adilition to one or more 
boiler makers .and one or more ojierators for the 
arc welding jjlant. The charge for the services 
of the repair boat varies somewdiat in dift'erent 
localities. On the Great Lakes a great deal of 
contract work is done, that is, a price i^ given 
on each proposed job. and there really is no 
standard price. 

The arc process is used rather than the o.xy- 
acetylene jirocess for marine w<;irk because the 
most important ])art of the work — boiler repairs 
— can be done only by the arc process. The cost 
of [iroducing the heat for welding is certainly as 
high with most electric outfits now in operation 
as it would be if the gas could be used. This 
high cost of producing the electric power is due 
to the high investment in the repair boat, the 
emergency character of the service rendered, 
which means that the boat lies idle a good per- 
centage of the time, and the practice of using 
steam driven equipment on a self-propelling boat. 
But owing to the fact that boiler repairs cannot 
be successfully done by the gas process and the 
enormous saving resulting from the application 
of welding in repair work, the electric welding 
outfit has become a recognized and indispensable 



30 



SHIP BUILDING AND REPAIRING 



part of the ship repair company's equipment. 
The actual cost per hour per operator on a steam 
driven outfit wliich includes air tool equipment 
varies of course with the continuity of the \v(jrk. 
On the Great Lakes the actual cost ])er o[)erator 
per hour, considering; investment and the varia- 
tion in the amount of work done is probably not 
less than $2.50 per operator (1916). The cost 
of operating the air compressor is an addition 
to this figure. The cost of operation in harbors 
on the sea coast probably does not exceed one- 
half the above figure on the average, due to the 
greater amount of work. Gasoline or oil driven 
equipment can be operated at a figure in the 
neighborhood of $2.00 per operator ])er hour, 
owing to the fact that a Hcensed engineer is not 
required. This type of equipment is to be recom- 
mended for small welding repair companies in 
all cases. The steam equipment is economical. 
however, for large slii]i repair companies on the 
sea coast. 

Regarding what to s])ecify for marine repair 
work, it is recommended that in all cases indi- 
vidual units be used ; that is. an individual unit 
for each operator. Unless the individual units 
are used, a machine of considerablv greater 
capacity must be installed in order that there will 
be no interference of one operator with another. 
The 150 ampere gasoline engine equipment is 
recommended for this work. 

Equipment 

A description of the various t\pes of arc 
welder adapted to ship building and repair will be 
found on pages 46 to 56. 




r 



I-'ig. 63A. Lincoln Arc Welder direct geared to a 10 IL 1*. Novo 

(iasoline Kngiiic, making an ideal outfit for ship building and 

repair work, where a portable niitfit is required. 




I-'ig. ()4. Weld in intermediate cvlinder of marine eiig'iie. 
iCvitrtc^y BOOM BOILER & IfELPlXG CO.i 




Fig. 63. W'elding a coal shuvel in the Great Lakes district. 

Arc Welding can he done at any point where an electric cable 

can be carried. 




Fig. 65. Gasoline driven unit on moinr truck. 



31 



ELECTRIC ARC WELDING 



Boiler Plate Work 




l-in. Ml Wildc.l ;.|i,ii. 1-. I. Hit, ,111 !,!,,« ,,lt i.ilvf ot vertiral 
boilt-r. Tile cornukil plati' was made gDoii. the leaky rivt-t heads 
were \\ elded nver with new ineti'l, and a new hlnw-olT valve 
socket welded in. Tin- repair saved replacinK 50 sq. ft. I't 
hniler plalini:. or scrapping the entire boiler. 




In liic iiiiiitixe shi]|j* nf the l;ir!;e railway s\s- 
Kins .if tlie cciiiiitry, the arc welding process has 
been iiseil fur a peridd of from six to eight years 
anil in nianv sh<i|is the process is used m.it only 
in the repairing ni nid htiilers. but in the manu- 
facturing of new ones. The wnrk in repairing 
(lid hnilers ma\' he grciitpe.l under the he.id of 
widiling in flues, welding in tulie sheet ,ind weld- 
ing cracks in the fire hnx. 

See ".Snggesti\e .\pplicati(ins," IVige 45. 

It has alsii heeii widel\ used fur general tank- 
\'. (Ilk. Ihe .\nierican Machinist, in a recent 
l->iie. jirescnts (piile ;i discussidii nil this use nf 
:'rc wadding, stating: ".Xdwhere is the saving of 
arc welding exemplitieil to a greater extent than 
in the manufacture nt steel t.anks. .\<it onlv 
ha\e the .icttial nianufacltiring ciperatinns been 
siniplilieil .and che.ipeiied liy the elimination of 
riveting and caulking, but the resist.ance of the 
finished weld In leakage nr rupture is much 
greater than that ni the riveted jdint." 

.\t a recent meeting of the I'lciiler L'ode (.'oni- 
mittee of The American .Societ\- of Mechanical 
I'.nginecrs. the following facts were jireseiUeil 
bv speakers before that cnnimittee bearing ])ar- 
ticiil.irly I in the use of welding for hniler and 
siinikar high pressure vessels. 

"The recent improvements in the art of weld- 
ing in the apparatus an<l in methods of testing 
the ]iroduct, notably in the electric arc [irocess, 
lave made it jiossible to make welded joints 
which are stmnger and more reliable than riveted 
joints ;iiid that the fnrnierh- accepted idea that 




tig. ti7, l-'inished arc welded "diamond patch" on bottom flue 
sheet of vertical boiler. Notice the neatness of the finished job. 



Fig. 6.S. Pressure Vessel made by Arc Welding, at tlie plant 
of the Leader Iron Works, Decatur, 111. 



32 



BOILER PLATE WELDLNG 



the WL-hk'd jiiint is an 'unkiKjwii i|uamity' has 
het-ii (li^iini\c(l hy in'cseiit day practice. (In this 
connection, photo-micrographs show that the 
thermal iHsturhance in the metal adjacent to the 
weld is negligible in the arc process and that the 
crvstalline structure of the metal in the weld is 
that "f n(irnial cast steel. ) 

"The autogenous welding processes are being 
used extensixely in all kinds of high pressure 
\essels. 

".\ manufacturer of such vessels has more 
than 2,5(M1,00(J in service to show that the per- 
centage nf failures on welded vessels is actuall\' 
Icjwer than on riveted vessels. The period cov- 
ered by this niamifacturer's experience is fifteen 
years and Imth electric arc and o.xy-acetylene 
jirocesse^ were used. 

"The demand f"r large high pics^ure drums 
lias reached the jioint where the thickness of the 
n;etal re(iuired to withstand the pressure is too 
great to be riveted owing to the excessive thick- 
ness of the metal obtained in the joint and the 
tonsei|uent difficulties encountered in exposing 
such a joint to the fire. The obsolete forge weld- 
ing process does not otter a solution to this prob- 
lem because of the unreliability of welds and the 
iiupracticability of welding vessels of such size 
in this manner. The autogenous w-elthng prcjc- 
csses otter a reliable and entirely ])racticable 
means of welding such vessels regardless <>f the 
thickness of the plate or size of drum." 

The boiler shop does not. of course, confme 
itself to making of boilers and pressure vessels. 
In a great deal of the other work the boiler slio]) 
does, the electric arc is especially adapted. This 
includes the manufacture of the follnwing class 
of articles : 



Tumbling barrels 
Revolving driers 
A'ats for breweries 
Tanks, vat? and flues 
Industrial cars 
Dump cars 
Clamshell buckets 
Converter >hells 
Spelter tanks 
Annealing pots 
Transformer housina- 
Oil refinery equipment 
Sugar refiner}- e<|uipment 



Cotton mill eiinipnunt 
.Special bodies for aiilonn 

biles 
Concrete mixers 
Tank car.s 
.Steel gondoIa< 
Steel box cars 
Gasoline tanks 
Feed water heaters 
Wagon tanks 
Fan and blower cases 
Hvdraulic accumulators 




with the I-incoln .\rc Wehltr. llie weld is only partially com- 

pU-teii and tht- "V" ■ili.qpcd joint ht-fore welding can be seen 

at the i-iRlil. 




Fig. 70. Welo 




lis ;i. lop 01 

stills vapor tight. 



od still siiowinK welding, which makes tiu-se 
The Standard Oil Co. use the Lincoln .Arc 
Welder on all tlicir stills. 



33 



ELECTRIC ARC WELDING 




I'ig. 72. W'fldiiiK in |il;ice "i calking "U rnnii nil vilK ma'If 
by The Standard Oil Co.. whtre Liiuulii Arc W'cldcts are ex- 
tensively used for boiler plate cuiistniction. Sncli coilsirnc- 
tion has stood years of s.r\ice. 




Fig. 7i. How the r.itl.oln \rr \\.l,i,:i su.ii.lili.v awk«anl cor- 
ner riveting. The edges of the angle irons were formerly ma- 
chined at their meeting edges and riveted to corresi'ondin.g strips 
on the inside of the sheet. They are now simply welded to tbe 
sheet and to each other at the coiner. 




111 tliis work. t.-k'Ctric arc welding comes into 
ilirect conijielition with riveting and for that 
reason a comparative cost of the two processes 
1- of interest. 

C(Ksf oj Jf'cldiii^r (Hid Riveting 

in order to compare tlie cost of riveting witli 
the cost of welding -we may take the amount of 
wiirk acci.imjtlished under given conditions liv 
the riveting gang, analyze the cost of the w irk 
ami compare it with the cost of doing the same 
work with the arc welding process. Taking the 
thickness of the jilate as ,''(i"i"cdi. spacing the 
rivets at 1 ' ..-inch, the size of the rivets at 
'j-inch in diameter, we can safely estimate that 
the riveting gang will put in 60 of these rivets in 
(■ne hour, under ordinarv shop conilitions. The 
analvsis ol the cost is as follows: 

I'igures ha-ed on conilitions in 1*^1'^ 

A'//7i77.V(; 

lo.ileniiakei's titiie. iiin- lumr $ .75 

Kivct liiickcr'.s titne, niu- lioiir 4,S 

I\i\et licater's time, otic hour 40 

One caulker's time, J • hour i7 

( )iie layimt man's time. ' .1 lioiir .V 

Two puiiclmicn's time. '4 hour .lO 

Two ereeti>r's time. ! ,i liour 40 

Two roll melt's titiie. ' .i hour 40 

I'otol ImI'oi- if 3.4 { 

I.eiiyth (jf riveted scatn. 7 It. 6 in. 

Pounds of rivets reqiiireil. .1.6. 

Cost of rivets, 10.8c. 

Power required to drive pneumatic hammer and 
caulking tool, appro.xiniately 10 K. W. hours. 

Investment per riveting gang, in air coinpres- 
.sors, with motor drive, stora.sje tanks, dis- 
tributin.g piping system, air hamtners. and 
other machines $8711.00 




Long. \'ertical Seam in Boiler Plate 
made bv .\rc Welding. 



tig. 7i. Lincoln Arc Welders at the slioji of Tlie tJhio iunlcr 

and Machine Co.. Cleveland. In the foreground are stiffening 

rings for boiler work made with the Lincoln .\rc Welders, which 

are used in this shop for a wi'le variety of work. 



34 



m fu ur mmm « m ui 



COMPARKD WITH RIVETING 



In order to get a comparative cost of the arc 
welding process, we will analyze the cost of 
doing the same work, namely making a seam 7 
feet 6 inches long, which is a lap joint, welded 
inside and out. The following is an analysis of 
the cost, also on 191'^ conditions: 

ARC WELDING 

One operator at 75c per Iir^ur I'm- 1'4 hi>iir-. $ .94 

No 1)iicker required. 
No heater retpiired. 

One man with a cliiiipina; h.inimer. ' '. li(jur .37 

One layout man, ' 4 hour 20 

Two punchers, ^g I'our 15 

Two erectors, 1-6 liour 20 

Twn riiU men, ]i hour 40 

Total Labor $2.2!'> 

Pounds of electrode rei|uired, 2.5. 

Co^t of electrode. 21c. 

Kilowatt hours rei|tiired t^ run tlie wehler, 

approximately 5. 
In\estnient in welding niacliiiie f"r one man. .$1,025(10 

Lalmr has changed considerably since this 
time hut riveting gangs' wages have changed with 
welder?' wages so that the comparison is very 
fair. 

It is to be noted from the above analysis that 
the labor cost item in the manufacture of boiler 
plate construction by ri\eting is ap])ro.ximateI\' 
50' ( greater than in the case of the welded con- 
struction. 

The amount of power required for riveting is 
double the amount required for welding. The 
investment recpiired b\- the arc welding appiara- 





l*'ig. 77. Storage t.ink made complete by electric arc welding. 

The flanged end is welded into tile sides by melting its edges 

together with the e(lt;e> of the side sheets. 





d^^ 



■^mi^iz. 



Fig. 78. This conical shfet was wel'Ie<l at tlie point shown, in 

Older to avoid a double lap at the edge of the work which would 

have been difficult to rivet. 




Fig. 



Annealing Put made witli the Electric Arc \\ elde 



l"iu'- ~*^. Cylindrical Tank in process of welding . This shows 

an ingenious method of mounting the tank on a "horse" and 

clamping the edges of the sheeti^ by means of two plates secured 

togfthcr by bol.v. 



Zh 



ELECTRIC ARC WELDING 




]''\g 80. Owing 111 lack ..f ni.TI.'rinl. pl.ltcs "f 'ufficii-iU ~i/<- cmld 

11. .} he >ecliri(l fcr tliis joli, I-.. in ■.iiKillt-r lll,ltc^ \v<r<- llu-rif..! i- 

wel.kil tMi;ttlKr with llii- iliiliic arc. ^:i\iiii; loiii. ilckiv. 




Fit;. SI. X'.Hiimii I'.-iii I"!' foi Siisar Builtr m.uU- I'f linilcr plate 

ill lliri-L- pini-^. Tlu- viilK-al fUctric wt-Idid stains in tlicse 

piccfs savi- a difficult and c\|.tii»ivt flali.uiiiK operation. 





Fig. .■-':, ll.tYuH-n ,,ll i.i) ^.i:-.n i; .q.p.M.itu-. I ni- IS 

welded all around circular seams and furnishes a good example 

ct the use uf weldiiiK in cnmhinaticm with riveting. Welding on 

this ioh saves awkward and expiii-ive flanging work. 



liijs is somewhat lii<;luT than in case of the rivet- 
in,;,' niachiiK-ry, hut tliis uf course is offset hy the 
liiwer n]jeratin.i,' cost. 

Strength of Jf'cld 

The ahu\t.- analysis has hern iiKule with refer- 
ence til jiihs which can be eitlier riveted iir weliled 
and it shiiws rather conckisively tliat it i~ cmi- 
siderahh' more ex))ensive to rivet a joint than it 
is to wt'ld it. 

The streiimii and (hnahilily nl' llie welded juint 
is greater than the ^anie iiniperlies of the riveted 
joint in the case analyzed above. The wehled 
joint ma\ he lOO'r efificient or as strung as the 
(iriginal plate which is a strength im|icissihli- in a 
ri\eted j< lint. 

In addition In the actual wurk outlined above 
riinforcing of boiler plate with steel angles otters 
a further opportunity fur the arc. 

|-"re(iuentl\- a \csst.l imist be nianufactnreil in 
whicli Idle of the plates is larL;er than any 'if the 
standard sizes id' plate. Two plates can then 
be butt welded together for this purpose: ihi> has 
been di.iiie with perfect satisfaction in a number 
(if cases in strainers, driers, water healers, etc. 

In the substitution of the welded joint fi ir the 
riveted jnint, it is recommended that in plate of 
i'',;-inch in thickness and over, wherever pussible 
a ioint be made as a lap joint rather than a butt 
iiiint. J'he amount of Iap]Mng should l)e at least 
I'our times the thickness of the ]ilate. 'Idle w nrk 
cm be held together preparatory to welilinL; by 
the use cif bolts and after the job is welded the 
bolt holes can be filled up and chipped ol'f. d'he 
use of a hammer for the purpose of hammering 
the metal welded on after the weld is completed 




l-ig, S.!. Sccti.m iif smnke-stack made l.> the _New 'S'luk IMi-.m 
Ciimpany by electric arc weldinc. 



36 



BOILER PLAIE WELDING 



ill order to "pack the metal in" slionld I)e ilis- 
coura^ed. 'I'liis is nf nn 1)eiieht and a positive 
harm may eume to the nu-tal frdni this ]iractice. 
The chipping tool can he used, hnwever, to (h-ess 
the ■\velded joint up to make it neat in ap])ear- 
ance. In case the welded jcini is to he suhjected 
to a pressure test and it is I'dund that there are 
small pin hole leaks, these leaks can he satisfac- 
torily repaired either hy chippinsj out a siuall 
amount of metal at tliat joint and tillinsj in new 
metal or by a small amount (if peenin^; with a 
center punch at the point at which the leak 
occurs. 

^\ here heaxy plate is hein^ \\ elded and more 
than one la_\er of metal is put into the jfiint the 
operator should always he re<pn'reil to brush the 
thick layer of oxide from the metal with a stitT 
brush commonly known as a castins,' brush cjr a 
I)ainter's wire Ijrush. 'rhi> is done si p that the 
metal throu,t;bout the whole weld will he as free 
from slag and oxide as possible. Neglect of 
this important jn'actice ma}- mean a leaking or 
sijongy weld. ' )n pi-essure tank work where a 
homogenetnis welil fi'ee from blow holes is an 
absolute necessity the ojierator shotdd hohl as 
close an arc as possible and the speed of the 
work should be sacrificed in order to use a com- 
paratively low current and consequently .get the 
metal into the weld in tin- best possible condition. 

Most of the Welding in boiler shoi)S should be 
done with the metal electrode, although on very 
heavy plate above ;'4-inch the carb<in arc may 
be used Uj speed up the operation. 

Whh the metal electrode 150 amjieres current 
for each operator represents the capacity re- 
fiuired in the welding machine. In the general 
practice of the boiler shop, the majority of the 
work would be done with /V.-inch metal electrode 
and 1?0 to 175 amperes current. 



Eqill p>l)lCllt 

-\ discussion of the various types of equipment 
available for boiler shop work will be found on 
pages 46 to 56. 




See il!ii^Irali<iii of liiiisluii u.uk tielnw. 



"•13^ 




FiS- S4. I'art of "lieader" m.i.le In- el.ctiu arc Wililiiii; a disli 
fliai>ed sleel llead into a cylimirical shell and welding in piece 
of |iii>e. Heads are made of ' ., iiicli plate, and tlr.- cylinder is 
's inch material. The cost of this op ration was .illc'per head 
l.y arc welding, against $1.50 per h.ad bv the acetvlenc process, 
fressure test of ISOU ]ionnds l>er s.iiiare inch did not show tiie 
slightest sign of l.akage or failure. 




Fig. 85 



37 



Lincoln .\rc Welder in the |)lant of The Standard 
Oil Co., Cleveland. Ohio. 



ELECTRIC ARC WELDING 



Drop Forge Shops 




l•'i^. S6. Kcpairing ilro]> fnigjngs !)>■ tlu' metal t-lectrnde priicess 
living n I.iiicuin Arc \\ t-Mcr. 



'I'lic arc wcldiiiL; prncrs^ is liciiii,' iiseil success- 
fully at the present time in the repair nf defects 
in (Iroj) foPijings before the forijint; leaves the 
sho]i. 'I'he wiirk is dcme to improve the appear- 
ance of the foryini;- rather than to im])rove its 
strength, although the correction of certain <Ie- 
fects does increase the strength of the piece. 
The most important class of forgings which re- 
quire the correction of small defects is automo- 
hile forgings. The defects corrected are low 
spots, parts not |)ro])erly Idled out, and certain 
kinds of Cold shuts. 

1 he detect is simpK filled in liy the metal elec- 
trode process and the excess metal ground ott 
with an emery wheel. It is not often necessary 
to re-anneal the forging after the welding jirocess 
fiwing to the very gi'eat localizatiiin of the heat, 
although if the piece is annealed after welding, 
the iioint at which the correction was made can- 
not be located. The work can be done verv 
ra])idly owing to the fact that the instant the 
operator strikes the arc, he can start filling in 
the metal. Xo preheating is necessarv. The 
lowest priced luan in the shop can do the w-eld- 
ing. 

The designation of the forgings iri he corrected 
by welding should he done by a competent fore- 
man (:)r the superintendent of the sho|). Know- 
ing that the luetal to be ailded will have a certain 
tensile strength and abilit\' to resist shearing 
stress and that it will have a very small degree 
of elasticity due to the fact that it is cast steel. 



there is little room for ditterence of opinion as 
to where to apply the welding process. The 
place on the forging at which the defect occurs 
has an important bearing on the question of 
whether or not it can be corrected. The service 
expected of a forging also affects the application 
of the welding process. It is evident that a de- 
fect of certain dimensions can be corrected if it 
occurs on an automobile lamp bracket which 
could not l>e safely corrected if it occurreil on 
a six C3linder crank shaft. The foreman of the 
shop, or the suj)erintendent knows wdiat to weld, 
it should not be left to the welding operator. 

Since there ;ire onl\ two welding jirocesses 
applicable to the correction of Haws in drop forg- 
ings, electric arc and oxy-acetylene, a comparison 
may be interesting. The cost of producing a unit 
of heat by the gas i>rocess is approximately six 
times the cost of ])roducing a unit of heat bv the 
arc process. ( )wing to the great localization of 
the heat in the arc process, ajjproximately three 
times the welding can be done with a given 
amount of heal as can be done with the same 
amount of heat produced by the gas process. By 
actual test, the cost (if gas for general work on 
;uuomobile front axles runs from twenty to 
twcniy-tive times the cost of electric power to 
do the same work. ( )ne operator with the elec- 
tiic arc can do at least twice as much work in a 
da\' as an ( j.x\'-acet\ lenc c)perator. 

The advantage has been claimed for the oxy- 
acetylene iH'ocess that it enables the ojjcrator to 
burn down to the bottom of a cold shut and thus 
lill in the whole defect. This practice is also 
]iossible using the carljon arc process, but the 
practice is dangerous. .V forging which shows 
evidence of having a deep cold shut in a part 
subjected to heavy stress shonld not be welde<l. 
.\ forging which has a cold shut which will not 
niaterially attect the usefulness of the forging 
will actually be in poorer condition after the 
defect has been burned out and filled in than if 
the dt'fect were not corrected at all. The appli- 
cation of the gas flame in sucli a case will over- 
heat a lai'ge amoimt of metal around the defect 
while the burning out is being done. After the 
area is sufficiently burned out. a comparativelv 
large amount of cast metal will he filled in wdiicli 
is known to be inferior to the metal of the origi- 
nal forging. There is no heat treatment which 
w ill bring the forging back to a condition equal 



08 



n II umnnniniiii urnnuD n 



m inn u oiuonuiiiiiiiDru'!!' 



DROP FORGE SHOPS 



to it-- cciiiililii)ii before the weldiiii; was ilnne. 
It i^ much better to simply till tiie defect to a 
depth of approximately a sixteenth of an inch 
with the metal electrode process whicli will imt 
materially ali'ect the metal surrounding the de- 
fect. 

Overheating the metal in a drop f urging is 
always undesirable, particularly in the case of 
the alloy steels used for certain autoniobile drop 
forgings. The high temperature reached in the 
gas flame and the electric arc affect the structure 
of the steel to such an extent that it can never 
111. made identical to the structure which has not 
been affected by the welding process. It is evi- 
dent, therefore, that the heat used for welding 
should be localized as much as possible. The 
oxy-acetylene flame will heat from three to five 
times the volume of metal in jierforming a given 
welding operation that will l)e heated when the 
arc process is used. The arc ])roduces heat in 
the metal at exactly the point wliere it is needed, 
while the gas flame jiroduces the heat external to 
the metal and blows it over a large area. 

The welding of defects on drop forgings is a 
delicate matter among some manufacturers at 
the present time. This condition of affairs ap- 
pears tn be due til the fact that the process is new 



rather than that it is imnmral. When the steel 
foundries first started to correcting defects in 
imjiortant locomotive castings there was the same 
feeling prevalent. In fact most of the welding 
was done in the dead of night and behind care- 
ful Iv guarded doors. Tliis was only five or six 
\ears ago. .\ow practically every steel foundry 
has one or mi>re arc welders, and every kind of 
;'. steel casting is welded in the presence of the 
inspectors. Defects in gun carriages for tlie 
Xavv Department are corrected in and nut of the 
Xavy Yards. 

The resiMinsibility fur .a droj) forging rests 
with the manufacturer. If he can make forgings 
at a price at which they can be sold at a jirofit 
and the forgings stand the service he can stay 
in business. If the maiuifacturer sends out bad 
forgings, he loses his business. As long as a 
manufacturer must scrap forgings with insignifi- 
cant defects I in them which his competitor can 
save, his price on the product will be high or his 
profit low. The present tendency of ])rices of 
automobiles does not permit the quotation of 
fanc\- prices on drop forgings. The welding of 
small defects on drop fcirgings therefore is a 
matter of business economics, and will undoubt- 
edl\' be solved in exactly the same m.anner as it 
has been solved in the case of the steel foimdries. 




1>^ 



lig. S/". I-uilmIii -\ic WtUfii lu U3C m large Drop Forging plant. 

39 



ELECTRIC ARC WELDING 



Commercial or Job Weldin: 




aclvct willi cl.ctric aic 



I'.Ncry cit\ III an\ si/t- lia^ a iuiiiiIkt of snuil 
sliii]is where wcldiiii; nl all ^nrts is ilmic. 



time acel\lene weliliiii; was the 
ill u^e in tlie^e sluipv. Tlu-v were 



I'lir a I'lii 
ehief prneess 

started, iiuistly, liy men wlin liad dune aeet\ leiie 
weldins,' in varimi^ maiuifaetnriiiL; [ilants until 
they had hecinne \er\ expert in it^ aiiplieatiuii to 
all flirts 111' wiirk. 

< hi startiiifi Imsiiu-ss for thenisehes. tliev nat- 
urally adopted the process with which the\- wn-rc 
familiar. They were prompted imt only In- tlii-. 
hut by the fact that it required only a verv small 
capital to Iniy the necessary equipment for acet\- 
lene welding. 

1 hese early shops have grown in niimher and 
have increased in size reiiiarkabh in the past 
ten years. The larger ones have now come to 
the ]«iint where there is a continuous stream of 
work passing through their jilants and they have 
been obliged to look ver_\- carefully into methods 
of reducing production cost. Competition has 
grown keen in pro]:iortion to the success which 
the early shops made of their business. 

< )\ving to tliis condition, many of the sho])s 
have carefully investigated and have been jait- 
ling in arc welding apparatus to take care of a 
great deal of their work. An investig.ition has 
shown that from 30 to 60 per cent of the work 
wliich is welded by oxy-acetylene can be done 
e(|ually well with the arc process, and what is 
more important, it can be done usually for less 
than half the cost of acetvlene work. 



There are undoubtedly cases in which oxy- 
acetvlene must be used in preference to the arc, 
such as the case of welding automobile cylinders, 
but this class of jobs forms onlv a small percent- 
;ige of the work done by a large commercial 
plant. Many such plants employ ten to fifteen 
operators and in a plant of this size, there is 
alw.ays work enough to keep two or three arc 
welding o|)erators busy using the arc. 

CoDi ptirative Costs 

The tables given lhi iiage are authentic, and 
will give the commercial welder a basis on which 
he can compare his present costs with thuse oi 
;irc welding. 

The importance of doing this wiirk at the 
lowest possible cost need not be emphasized tor 
every welder knows that every cent he saves on 
any gi\en welding job goes into his pocket as 
that much extra |irofit or in other cases it enables 
him to bid lower on desirable work and secure it 
at ;i goocl profit against competition from smaller 
shops who are tiguring work for acetylene weld- 
ing. 

The be--t |iossil)le liasis for comparison is the 
actual installation of an arc welding outfit in 
the commercial shoj) and a thorough trial cover- 
ing a period nf two or three months' time. This 
sort of a trial can be arranged at a slight expense 
and has jiroven a means of cost cutting to com- 
mercial welding shops in Detroit, Pittsburgh, 
I'rovidence, 1\, 1., Cleveland, and other places 
where it h.is lieeii tried. 



Portable Outfits 



'hie siiurce nf ]iriifit to the commercial shop 
is that class of work which cannot be brought 
to the welder, but which operators must go out 
to do. J'or this jiurpose the Portable Arc Weld- 
ing Outt'its are made whicli can be operated con- 
\enientl\ .ind at \er\- low cost. 

Erjnipn/ffif 

The commercial weldinsj shop needs a welder 
of at least 200 amperes capacity. This will be 
suitable for ;in\- metal electrode work or light 
carbon electrode welding. 

Two or more 150 ampere welders are of course 
to be preferred to one of 200 ampere output, as 
this will allow a larger number of operators to 
w firk at the same time. 

Illustration and com]ilete description of weld- 
ing equipment suited for commercial work will 
be found on pages 46 to 56. 



•40 



GEiNERAL MANUFACTURING 



General Manufacturing 



riir UM.- ut wcldniL; in rrpair wcirk has jicr- 
liaps been over emphasized by all manufacturers 
of welding apparatus. ( ipp(.irtunities for this 
work are most easilv fciund and it is very easy 
t<i demonstrate the ^axint; made. 

The field fur this class of work does not com- 
pare, however, with the field for general manu- 
factui'ing work, where wi-lding can be used to 
lake the place cjf riveting and nthcr method> of 
joining metal parts. 

There are hmulreds u\ such applicaiiiuis of 
\\'elding now being made. In these cases the 
work has either been accidentally discovered by 
the manufacturer himself, or some welding engi- 
neer has carefulh' sought out this ai}plication 
and demonstrated it to the manufacturer. 

It is exeeedingh- difficult tn obtain data or 
photogra])hs on this clas.s of work. The manu- 
facturer wlio has successfully applied it. is nat- 
urally averse to giving out the fact, since he is 
usuall)' making savings which are important to 
liim in meeting competition. .Strictest secrecy is 
often maintained regarding this work. 

]'"ach mamifacturer is therefore obliged to find 
liis own ;i]iplication for .-irc welding to a great 
extent. 

We have endeavured to present on page 45 cer- 
tain i\pical illustrations which show not any jiar- 
ticular manufacturing process, but the general 




Fig. 8K.\. .\sphalt .Mi.\fr willi arc wL-liieri Heating Jacket. 

Welding saved TO'^y ovtr ri\etiiig and increased jacket cap.-icity 

by avoiding ttangt-s an<l rivets c.n the inside. 




I'ig. 8'J. Welding steel slie^'ts together tu form gear cases, 'riie 

Incs on the inside of the case are also welded on. Jobs similar 

'o this can be found in hniidrc<ls of tnannfactiiring t>lants. 




l-'ig. 90. l-'actorv prorlnclion of anto starter framt 
Lnicoln .\rc Welder. 




1',^, ■-! ■ CKIXDI.VO. 

l.\(i. .^leti »'» in . ..,..,.. :... .\..v;, .tfler the weld 

welding a steel plate run and rim has been grotinrl d' 
bolting it to steel sliokes. give Mncjoth snrl'a' 



Stcc 
111 the 
iwn to 



41 



ELECTRIC ARC WELDING 




Fig. ^'J. Street car entrance showing use of electric welding 
in car manufacture. 




Clara.ye heater electrically weldeil. This is a gfotl 
example of welding in light sllcjt steel. 




a])plication of weliling so that each nianufatciirer 
can apply the jiriiiciples sliown in these samples 
til his own jiarticuhir prohleni. 

Sheet (iiid Plate Jf^eldiug 

The apphcation of welding to this class of 
material has been covered in boiler plate work. 
The range of work is so witle here that there is 
iKi possibility of giving definite rules covering 
the subject. ITie best than can be done is define 
llie limits within which welding can be success- 
fully perfornieil on sheets and plates. 

(Generally speaking, arc welding cannot be suc- 
cessfully aj)plied to steel sheets of less than 20 
gauge. In certain instances where sheets are 
weldeil to reinforced angles or are backed wyi 
bv Slime heavier material, it is jmssible tn welil 
thinner material successfully. 

Reinforcing of sheets or ])lates by angles, rims, 
etc., presents another possibility for arc welding, 
ll has been successfully apjjlied for welding angle 
iron supports on tank wagons, reinforcing rims 
in large storage tanks and other work of this 
general nature. 

Pif^e Jf^ elding 

The advantages of welding for pipe construc- 
tion have been a subject of careful investigation 
bv The Xaliimal Tube Co.. and others interested 
in this subject. 

It has lieen found that welding gives a more 
|iermanent joint in jiii.ie than the couplings ordi- 
narily useil, that it gives a strength equal to that 
of the solid jjipe and reduces the tendency to 
leakage at joints Ijv eliminating couplings, the 




Fig. 94. Screw conveyors made by arc welding the spiral 
-te.-I \anes to a central shaft. 



Fig. 9.V Welding door hangers f,M tircprnof steel doors. Th 
square tuhes on the horse are also arc welded on the seams. 



42 



GENERAL MANUFACTURING 



whole being practically (Hic unbroken length of 
pipe. 

These advantages are of special importance in 
the construction of superheaters and similar ma- 
terial made from pipe products. 

A development of this pmcess is the welding 
of flues in locomotive boilers which has been very 
widely practiced in railroad shops and locomo- 
tive manufacturing plants. 

It is the present theory that webled pipe lines 
reduce electrolytic action and corrosion. The 
welded pipe presents a ccjntinuous conductor in 
which the resistance is lower than in CDupling 
l)ipe, thus reducing the tendency of the current 
to jump joints and set up electrolytic action. 

This use of welding is aiiplicable not onlv in 
shop manufacturing work, but in laying of pipe 
lines and can be taken care of t(.) good advantage 
by a portable arc welding set, which either takes 
current from the trolley or electric supply line. 
A portable welding set, driven by a gasoline 
engine or mounted on a truck and driven by a 
truck engine will accomplish the same result. 

Repairs 

The re]>air of defects in manufactured pieces 
has already been discussed under the subject of 
steel castings and forgings. where arc welding 
has thus far had its greatest a])plicatii m. 

There is undouljtedly another wide field in 
building up of [iressed metal parts which come 
imperfect from the dies and which have cracks, 
"short sides" or similar minor defects, which 
could be readily repaired by adding new metal. 




y^^r\ 




t 



") 



V 



K ■■' !'-' 



( r.'ickeil iiiKi'i i '■■1 Ijy I.iiici)ln .\ri- Wclili-r. Cnmplftod 

wrld u.is Milt ' iH.Uk'h tu Ik- easily Tnaclliiieil. 




i 



Eig. 97. Flexible shaft fur automobile, arc welded. 




I-'iK. '-'^- Welding defects in steel tul)es with an clecii ic ai 
welder. 




Fig. 96. Tanks for disli-washing iiiacliincs weldt-d \Mth a puit- 
able Lincoln Arc Welder, shown in illustration. 



'W^W^^' 




Lm 



StrrI M.-iciiUKM; 
Arc Welder. Ilettc 



platr 



a cast iron bed 



43 



ELECTRIC ARC WELDING 




l-'ig 100. Welded patch on ^ecl kcttl -. Tlie \>:i\ch is cl-;irly 

slu'wu and also corrcul -d pdrtinns around ilu- p;itcli which wt-rc 

built ii|' by arc wcMiiii;, 





Jed^ i 



Fig. 101. lluLslmg l-.iigiiic UmiUt. in ninth a large i)art of 
the tlange had been badly corroded by use of poor water. This 
<:lainage was completely repaired by a Lincoln Arc Welder, sav- 
ing the bniler which would otherwise have been scrapped. 




The rejiair nf hnilxcn macliinery di' parts can 
l)c made quickly ami at low cost by the arc weld- 
ins^ process. Unless the plant is a large one and 
would have a consideralile am<iunt of this work, 
acetylene would be cheaper than arc welding, but 
where there is enough such work to keep an 
operator busy a great portion of the time, the 
aic welding wcdild be found most ecnnomical. 

The general nature of such repair work, fol- 
lows under se\eral headings. Huh holes often 
become worn and necessitate replacing the worn 
piece with a new casting. This can be avoided 
In- lining the wurn hole with new metal then 
redrilling it. Hearing surfaces on slides, cams, 
etc.. are rt'p.aired by Sdinewhat similar [irocesses. 
I';iUhes ,-u'e applied on ladles, tanks, anil vessels 
u<ed ill dilt'erent manufacturing processes. 

.^teel mills have found it economical to install 
arc welders for the purpose of repairing wobblers 
in the- idlling mill. The ends of these wobblers 
are built up with new steel to original shape, sav- 
ing the cost of a new roll casting, which is much 
mure expeiisivi' than the ordinary casting steel. 
Work is also being done successfully on the 
working surface of the roll. 

-Steel shafts are built up in somewhat the same 
m.inner. new material being welded on to the 
worn end. and the shaft then being put into the 
lathe ,111(1 turned down. 




F.g. 



-. Steel part., mcorrectly machined bnilt up by the arc 
\elder and afterwards re-machined In projier size. 



lig. 103. This steel casting was wrongly tnacbined. 1 he bore in 

the center being machined out too large. This shows how it was 

bnilt up with a Lincoln -\rc Welder and afterwards machined 

to the proper size, saving the casting from the scrap heap. 



44 



iluimiiiiDti) iiiiiiniiiiiii I 



II niiuiyiDui (luii iiiju]i II iiiK ijiFiji nil 1,11 



ELECTRIC ARC WELDINC 



Suggestive Applications 




M 



Fig. 104A. FLUK WELDING. 2" Fine 
— LcH-omotive Back Flue Sheet. Actual 
Time 2 minutes 2" Flue; 7 minute? 5" 
Flue. Electrode 2" Flue — ^d*"— 90-100 
Amp. 5" Flue 5/32"— 120-130 Amp. 
The total tuue to weld a complete set of 
lilies depends on the condition of the 
Hues and Bue sheet. A fair average may 
he calculated from the above figures hy 
adding 50%' to the total time for rest 
periods. 




Fig. 10414, FI.tE W ICl.Iil.Ni;. I I'ut iln. iti .:j 
if it were not to be welded. 2, Send the .ngine 
out for a few trips to let the tuheE! take their set. 
3. San.I blast the thie sheet. 4. WVld Hues. A 
heavy head of welded metal around the flue is not 
desirable Put on the smallest hoad that can l)e 
thoroughly welded to both fbie and sheet. 




Hg. 105. liflLDINO VP OI»E».\TIONS (Note 
that Uie weld is easily machined.) 5/32" Electrode 
130 Amp., 20 Volts will deposit one pound of metal 
in approximately 30 minutes. 3/16" Electro<Ie, 175 
.\nip. . 22 Volts will deposit one pound of metal in 
approximately 20 minutes. Using 5/32" Electrode, 
one cubic uuh of steel may he deposited in about 
.'■2 minutes. The metal when deposited on mild steel 
hy (he metal electrode process will always he soft and 
easily machined. The carbon electrixle process should 
t)e used for building up operations only when the 
huilt up piece can he later annealeil to Uke out con- 
traction strain. 



Fis. 10! r, FLANGED HEAD 
B.\( KEli INTO SHELL. 



V'X 






Fig. 104D. FL.\NGED HEADS 

BOILER PLATE. 

^" Plate — Speed — 7 ft. per hour. 
5/32" Electrotie 130 Amperes. For 
High Pressure, jointa should be welded 
inside and out. 



I-ig. 104G. Typical welding job on ^s inch plate, aiul imgs 

made of ^^ Inch stock. 

Using 200 ampere welder, J^inch electrode welding 14 feet 

of seam per hour. 




Kig, luJE. BOILER PL.\T£ WELDLNO. 
Size 
Ff. per Hr. Electrode Current 

l*" ^ -^/Si 110Amp3. 

^„ ^ 5/32 120 Amps. 

'-^ *3 H-3/16 150 Amps. 

.\hove figures include straight welding time 
only. Loss of time in handling the job 
must he taken into account on each job. 
Vertical or overhead welding speeds are at 
least 50"^ below speeds given above. 
'%" wire is usetl to fill in bottom of seam 




i-ig. 104F. WELDING IN PLACE OF 
' ALKING. Speed of work depends on 
• tnount of metal added. Strength of joint 
may be raised 25% doing the work at three 
imes the welding speed given in table. 
l-age 6, for any thickness plate above ^i". 
This makes a single riveted joint equivalent 
to a double riveted joint and makes a 
ilouble riveted Joint as strong as the 
original plate. Joints welded in this man- 
ner stand much abuse without leaking. 



45 



EQUIPMENT FOR ELECTRIC ARC WELDING 



How to Buy Equipment for 
Electric Arc Welding 



Electric Arc Welding ha- had a marvelous de- 
velnpment durins,' the jiast three or four years. 

The absolute necessity for tremendous pro- 
duction in war times gave to electric arc weldmg 
the impetus that was necessary tn its recognition. 

Unfortunately, this rajjid develoimient of arc 
welding has been taken advantage of and the 
process has lieen recommended for work which 
it cannot satisfactorily do. l{lectric arc welding 
ajiparatus has been devised over night by those 
with no practical e-xjierience in its manufacture, 
who are endeavoring to make the most of the 
unusual demand f"r this ec|uipment. 

Unless this unfortunate situation is immedi- 
atelv corrected, electric arc welding is going to 
fall into discredit among hrms who are usmg it 
for impractical purposes or under wrong condi- 
tions. For instance, the statement is being widely 
made that any metals whatever can be wehled m 
the electric arc without pre-heating. Such over- 
statements of the adaptability of the process 
cannot but do harm not only to those who would 
us it, but to those reputable manufacturers who 
are endeavoring to build up the welding industry 
on a substantial liasis. 

The Lincoln Electric Co. feel that they owe it 
to the electric welding industry and to those who 
may lie prospective users of this process, to make 
a frank and complete statement on the present 
situation in the industry. This Company is in 
position to make this statement by reason of the 
fact that thev are the pioneers in the successful 
commercial a|iplication of electric arc welding in 
this country. 

Their first accomplishment was the use of the 
electric arc to melt new steel into defects in steel 
castings, thereby saving the casting from the 
scrap heap. The Lincoln I\lectric Co. devised the 
apparatus for this purjiosr and has sold it to 
]iracticallv every leading steel foundry in the 
United States. 

In this work, they have endeavored always to 
be conservative in their statements as to what 
the arc will do and confidence in their judgment 
is shown by the fact that steel army truck wheels 
and other parts for ordii;mce use were fully ap- 



[iroved after having been welded with the electric 
arc. 

The following information is issued by The 
Lincoln Electric Co. to intending purchasers of 
ecpii[)nient for arc welding. In submitting this 
information, every effort has been made to con- 
fine the discussion to absolute proven facts and to 
give oiilv such information as would be of con- 
structive value to the pros]iective purchaser and 
to the electric arc welding industry. 

niuit Metals Can be JVclded 

( ieiier.alK- sjieaking. iron, steel and the various 
alloys of these metals can be welded successfully 
with the electric arc. As for the other metals, 
aluminuin, brass, bronze, copper, etc.. there is a 
certain amount of welding that can be done on 
these metals in a commercial way. However, any 
statement that all of these metals can be welded 
without any trouble and without pre-heating is a 
distortion of the facts. Any firm which claims 
that any metal whatever can be commercially 
welded condemns itself by its own statement and 
the intending purchaser would do well to avoid 
anv organization which makes such ckiinis for 
the electric arc welding process. 

Conimcrrially Practicable Jf\-'Jdnig 

Right here it is pertinent to say that there is a 
vast difference between wdiat can be welded as a 
matter of show or dis])lay and what can be 
welded commercially. 

.\ highly skilled operator with years of exjieri- 
ence and apparatus which he thoroughly under- 
stands can perform work on display which can 
never be duplicated in a factory with the sort 
fif help available for such operations. 

In advising on electric welding. The Lincoln 
Electric Co. never advocates welding for any 
work where it cannot be done by a reasonably 
skilled operator under normal shop conditions. 

W'e would advise any intending jntrchaser of 
welding equipment to insist upon a test in his 
own shop with his own workmen under actu.il 
sho|) conditions before purchasing equipment. 



46 



LINCOLN ARC WELDER 



The Lincoln Arc Welder Will Do 
More Work Per Day 



Arc welding apparatus is ]iurchascii lUr liie 
purpose of doing certain work. The best arc 
welder to buy is the one that will do the most of 
that work in a day and do it at the lowest cost. 

livery prospective purchaser of welding e(|uip- 
nient should kee[i that simple thought first an<l 
foremost in bis mind and not lose sight of it in 
considering the mass of technical sjjecilicatinns 
which are necessarily submitted with everv bid 
for electrical apparatus. 

The work turned out by the e<|uipment is 
something which any buyer can judge without 
any technical knowledge whatever and it is <inc 
thing which determines tlie value n{ ibe ecpiip- 
nicnt to the purcliaser. 

Tlir Lincoln Arc Il'clilcr icill do Ji> per cent 
more leeldincj work per ihiy under actual contincr- 
cial iceldiiif/ conditions than any other electric 
-leeliiiioj cijuipnicnl made. 

riiis is a wcl]-C(insidcred statement bascil on 
the results of man\- competitive tests and it is a 



Fig. 106. This is tile 
type of Lincoln .\rc 
\Vetder supplied for 
heavy steel foundry 
work where current 
up to or exceeding 
400 amperes is re- 
quired. 




claim which The 1 .incdln Electric Co. are pre- 
pared In prove at an\' lime or place where weld- 
ing is being done CMiitinuoush' by ciimmercial 
operatnrs. 

The following art- ihc facts on a few tests 
recently conducted by prospective ]iurcliasers to 
determine the relative \ able of the Lincoln 
\\ elder and three other com[ieting machine^, 

Jn each of these tests the articles welded were 
standard ])roilucts being produced in large quan- 
tities and in each test the o]ierator of the machine 
was an emplij\ee ot the comp.mv that proposed 
buying the e(|uipment and the same operator 
worked on all of tlie clitTereiit t\]ies of welders. 
.\'ames of tliese liiius are not published here 
because tliey ilo not wish to ba\e the jiarticulars 
ot their slioji jiractise known, but further facts 
can be lumished to any one on recpiest, or better 
-till, a similar test e.in be arranged in his own 
'•bop for .any iiitending purchaser of welding 
eijuipmeiit. 

TK.ST No. 1 

-\\ eraae 



-Make 


Time W'cldiiiij 




Relative 


..f Welder. 


One Piece. 


s 


)eed Percentages. 


-Make -I'." 


24 mill. 20 sec. 


Liiici 


j1ii welds 60'; more 


.Make ••(■•• 


^9 min. .SO sec. 


I.iiu-i 


iln welds lOO'"; more 


Make".\" 


1" mill. ?t?i sec 


Line 


dii welds 18'; ni.)re 


I.incnlu 


1.1 mill. ,) slc. 







Xiite: The inaniilaelnri r's •■nt;iiU'er repurtiiiy" on 
lliese teets eomnunleil as ti>ll'i\\>: "Linciilii weld .yood 
clean fracture, .ynod penetraticn." (In eaeli of the other 
three machines testul he re]iorts eiilu-r poor penetration, 
porous weld or both poor penelialion and pon.us weld. 



Stabilizer 



LINCOLN ARC WELDER 



TEST Xo. 1 
Ataki-iif X<i. of I'inislieil Relative Spet-d 

Welder Pieces per Day Percentages 

Make "A" 11 I.iiioilii uelil> J/' ; ni'Te 

I.iiiculn 14 

TEST Xo. 3 
Xo. of 

Fiiiislied Ten>ile 

Make of Pieces Relative .S])ee<l .Strength 

Welder Per Day _ Percentages ..fWeld 

Make"B" "l4^ Lincoln welds 43' i more 3V,7(Klll>s. 

Make-C" 16'. Lincoln weld- 21 '; more 40.614 llis. 

Lincoln JO 46.M.niis. 

Thf last item i)f tensile streiiijth was ackied in 
this test to deteriiiine whicli welder ])roduced tlie 
best weld regardless of speed. In this also, the 
Eincohi Welder won by a safe margin. 

'J"he importance of such tests as these cannot 
he (iver emphasized for it rejiresents the only 
method by which the relative merits of different 
n;achines c;in be t.airb ilecided. 

The "R{iti>i<{" of FJc/tnc If ciders 

Because the welder is a ])iece of electrical 
api)aratns, it is nrdinai'ily rated according to the 
lumiber of amperes current il will deliver. This 
rating is supposed to be a measure uf the welding 
work which the machine will do. This is not 
actually the case, however, imless full particulars 
are given as to the conditions midcr which this 
current is delivered. 

For instance, two welders, each I'ated to deliver 
200 amperes are imt necessarily capable (if doing 
the same amount of work. .\s a matter of con- 
forming to general custum on electrical apparatus 
The Eincoln I'.lectric L'o. rate their welders on 
amiieres current ilelivered. The Lincoln rating, 
hiiwever, gi\es the ntunber amjieres current 
which the welder will deliver at the voltage neces- 
sar\- for actual welding. Some nther manufac- 
turers give, as a rating, the maximum current 
which the welder will di'Iiver f(ir ;i short ])eriiKi. 
I'.y far the most satisf.ictorv method and the 
one which Tlie l.incdin l'".lecti-ic Co. recommends 
is to buy welding eqiii])ment which is guaranteed 
to do certain welding work regardless of anv 
arbitrary rating. This The Lincdln l^lectric Co. 
is prejiared to do on any kind of welding work. 

Jf'liy The f.incoln Jf'orks Faster 

The Lincoln .\rc Welder will do more wi irk 
per day because it is an easier machine to operate. 

1 he heat for arc welding is generated bv elec- 
tric current jumping or arcing from the welded 
piece to the electrode which the operator holds. 

The voltage of current necessary to make it 
jump across this gap dejiends upon manv things. 
Among them is tlie distance of the electrode 
from the welded piece. 

The slightest movement of the operator's hand 
w ill increase th.it distance and increase the volt- 



age. These conclitions change so rapidly in actual 
welding that at one instant there will be almost 
lio voltage required — the next instant a consid- 
erable voltage may be necessary. 

The Lincoln Arc Welder takes care of these 
variations better than any other type of equip- 
ment. The arc does not "go out" so easily — 
the operator is not fatigued by an effort to hold 
llis hand ])erfectly steady nor does he have to 
work slowdy to kee]) the arc in operation. 

L(ii)iiH(ited Steel Frame 

The fact that the Lincoln .\rc is easy to operate 
is due to the construction of the magnetic field 
or frame of the welder which is built uj) of steel 
laminations or sheets. The electrician will readily 
understand that this type of construction jiermits 
a very rapid change in the amount df "magnet- 
ism" or "flux density" and this in tiu'n makes it 
possible for the electric current tn adjust itself 
.almost instantly t" any ilem.and. The complete 
magnetic circuit of the Lincoln Welder is lanu- 
nated instead of the pole |)ieces akitie. 

The Lincoln Stabilizer 

In addition to the laminated steel frame the 
Lincoln Arc Welder is priiviile<l with a .Stabilizer 
which acts upon the electric current iinich like a 
flv wheel does on anv other piece nf machinery. 
It stores up energy which permits the machine to 
take cire of an extraordinary demand without 
any tiduble. 

Operators Like The Lincoln 

Cnder present Labor C(inditi<ins this fact is of 
the ntnio-.t inipi irLiiice. ,\nything which tends to 
produce a nuiscular or nervous strain U])on the 
workmen will lead to their doing inditYerent work 
o; cause them tn leave the job altogether. 

Most welding work dejjends for its success 
upon careful, painstaking attention and this can- 
not be had unless the equipment is easy to o[)er- 
ate. On piece wdrk this ease of operation is 
especially essential and piece work operators in- 
variably favor Lincoln e([uipment where they 
have had the opiiortunity to observe it along with 
u'her types. 

The Steady Arc Means Good IV elds 

llecause of the laminated frame construction 
and stabilizer the Lincoln W elder jiroduces an arc 
w hich is steady and easy to maintain. The fact 
that the arc is easy to maintain with a Lincoln 
Welder tends to produce better welding work, 
(.ontinuous breaking of the arc and the necessity 
of frequent starting produces a brittle, porous 
condition in the weld. The best welds are made 
where the arc is kept steadily in operation and 
the metal thus deposited is homogeneous and 
stronsj. 



48 



LliNCOLN ARC WELDER 



u uiiui ui niu u u n nu nu lun I 



Fig. 107. I.incolii Arc 
Welder for use wliere 
the shop supply is 
direct current. Any 
(lectrician can under- 
-rand this et]uipment. 
It is all stan<iard. 




Fig. 108. Lincoln .\rc 
Welder for use wlierc 
the shop supply is al- 
ternating current. Note 
the simplicity of tins 
etpiipnient and freedoni 
from any coini>Iicatt'<r 
switches or electrical 




t itnerator 



I (Milr'>! Staliili/er 



Stabilizer 



Lincoln Arc Welder Is Standard Equipment 



'I'lu- illustratidiis ])resente(l in this huok show 
the standard Linccihi Arc Welder. W'c urge the 
inlenthng purchaser to take these iUustrations. 
with the simple explanations under each one, and 
compare them with the illustrations of any other 
arc welding equijiment he may he considering. 

'J'he entire ahsence of any solenoids, cla])])er 
switches or anv other complicated devices will be 
noticed. The Lincoln .Arc Welder consists 
siinplv of ; 

1. -\ .'standard Motor driven by the shop cm-rent, 
whatever it may be, alternating current or 
direct. ( This furnishes power to drive the 
generator. Where electric power is not avail- 
able ; belt driven or gasoline engine driven 
welders are supplied.) 

2. .\ .Standard Generator, delivering current at 
the proper voltage for welding. 

vi. .\ Stabilizer to give permanence and stability 
to the arc. 

4. .\n electric control panel with simple knife 
switches and meters for adjusting the amnunt 
of welding heat. 



The simplicitN of the Lincoln .\rc Welder can 
be understood by any person at a glance and we 
would further advise, if possible the examination 
by a competent electrician of the competing types 
of apparatus to determine which would be the 
simplest and cheaj)est to maintain. 




l-'ii;. 109. Liticiiln .\ri- WclcU-r hilt (lii\i-n. This type of welder 
is used wlieie ,i phiiu i^ ii"t wippliol with elfctiic power. 



49 



FOR RAILROAD SHOPS 




Fis- 110. I'oilalili- Lincoln Arc Welder 
uilli..nl Cover. 1... K,iilr,,;ni .'^h..|i T'e. 



Lincoln Arc Welder for Railroad Shops 



'llii-> ei|uij.niem is the -anR- in all respects as 
the stamlard weldiiii; nuttits. I'm- convenience 
in railroad shoi) nperalidn. h<i\ve\iT, it is ninnnled 
on a specially (lesi<^aie<l tnuk which iieniiits it t(j 
be iiKixeil readily al>Mut the slidp. 

SlH^ciiil .-idvtiiitdi^cs of Li/iff/i/i 
Jrddcrs 

Ihis iiutlit is mlended li lake care n{ nw 
cperalur and can he placed at any puiiit in the 
shop where an electric iimtnr is installed. In 
other winals. there need he ikj special prii\-isi,in 
for the wekhnt; outfit anil im special wirint; an.l 
re-arrani;enient of the shop. 

(•tiler tyi)es of welder are desianed to take 
care of several ojierators from iine machine. The 
disadvantage of this system is that it requires 
a low tension (hstrihutinj; sxstem carried frnm 
tlie welding machine to any station where weld- 
ing is to be done. Such a system requires large 
copper wire and is a very expensive installation 



1(1 make, ami it diics nnt offer any adxantage 
whatever. 

The l.iiiciiln Arc Welder can always he taken 
to the place where the lucnmotive is standing 
and welding work can go on at the same time 
with other repairs. With other systems, the loco- 
iiKitixes all have to be hmught to s|.)ecial stations 
fur welding work or a k>w tension wiring system 
has to he carried over the entire simp. 

Instead of mo\ing the heavv lociniiotive about, 
the Lincoln Arc Welder, on its light truck, can 
he taken anywhere even for a few minutes work. 
Ibis is an important advantage of the Lincciln 
l\ pe of equi])ment. 

With the Lincoln Arc Welder anv number of 
opi-rators ilesired can work on the same engine 
witlmut interference, something which sluaild 
not be overlooked. 

.Should occasion arise to use carbon arc weld- 
ing, needing a welder of greater capacitv, this 
can be ])rovided by connecting two or three indi- 
\idiial units. Dccasion fiir this will practically 
never arise in the railrnad shop. 



50 



LINCOLN ARC WELDER 



EcoiioniirnJ U'itli Power 

The Lincoln Arc \\ elder uses nci resistances 
of any sort in the line to cut the voltage of the 
machine down to that required for welding. The 
equipment generates at all times the correct 
amount of voltage re(|uired at the arc. This, 
together with the fact that the equipment is very 
simple and efficient in operation, makes the Lin- 
coln \\'elder the most economical from the point 
of view of power consumefl. This is an impcjr- 
tant point as the cost of current for a welding 
machine will amount to many times the cost of 
the machine itself ilurir.g the life of the machine. 



at the arc the I'.xact amount of current needed 
and makes unnecess;u"\' the use of resistances. 
This princi])le was widely criticized hy competi- 
tive manufacturers hut today practically every 
successful maker of welding equipment produces 
the variahle voltage type of machine in some 
form or other. 

Thdse who foljnwed in the held have neces- 
saril\- Ijeen oljliged to use a plan for obtaining 
variahle voltage which had already been tried out 
and rejected bv The Lincoln Electric Co. The 
design at present employed by The Lincoln 
l-^lectric (o. is thm-oughly protected by patents. 



The IJiicoln Electric Co. JFere "Altcnujt'in^'' Current JFelding 



Pioneers in the JVeldins Field 

This statement is not an idle buast, but a fact 
worthv of consideration by every purchaser of 
welding e(|uipment. This company has in opera- 
"tion toda\' more arc welding outfits than all of the 
other manufacturers of such apparatus combined. 

The Lincoln Electric Co. originated the so- 
called "variable voltage" welder which delivers 



During the war a great amount of interest was 
excited h\ claims that alternating current could 
be successfullv used for arc welding. Practically 
everv attemj)! to use alternating current for this 
purpose, however, lias prdved a failure, due to 
the fact that the apparatus is very difficult to 
operate and the welds produced are brittle, 
pi irons and unsatisfaclury. 




ig. 111. Liiiculn .\rc Welder driven by g.lsoline engine. 

This type of welder can be mounted on motor truck or on 

casters, and taken to any place where welding work is 

required. 



51 



LINCOLN ARC WELDER 



Multiple Operator Jf'eldin^ Outfits 

Welding outfits have been designed from which 
a large number of operators could work at one 
time. This outfit makes necessary a resistance 
in series with each welding arc. resulting in tre- 
mendous loss of |)owder which quickly outweighs 
any saving which may be made in the first cost, 
bv buving an outfit which will serve a number of 
0])erators instead of an individual outfit for each 
operator, .\notlier difficulty with this apparatus 
is the interference when all ojjerators happen to 
work at the same time. The current varies 
greatly and the result is uneven work. 

Such an outfit can be used only when there are 
an average of over ten ojjerators and even then 
there is a decided disadvantage. 

The individual imit is to be preferred at all 
times because in case of lireakdown or trouble 
only one welding ojierator is atifected. 



The Lincoln Arc Jf elder Is Bucked 

by a Complete Service 

Organization 

IClectric Welding is and has been one of the 
only two sources from which The Lincoln Elec- 
tric Co. derives its income. It has therefore 
been advisable for them to develop a high class 
t>rganization. 

In fourteen principal cities of the L'nited 
States there are now Lincoln welding engineers, 
men who have served their apjirenticeship in the 
di liferent applications of welding and who are 
prepared to advise with the manufacturer upon 
any welding {jroblem which may arise. 

These men are in constant touch with every 
user of welding equipment and are under the 
direct supervision of tiie men who have practi- 
cally created electric arc welding and brought the 
]'rocess to its present stage in this country. 




\inn. -[lw,^^ jMii ipi nil. i i ] 1 1 j ] 1 1 n 1 1 1 .11 iin i-iiiLniii 1 . ii. l 11 1 1 xi^miiiK 1 't , -, 1 1 1 1 1 1^ 1 1 1 . wlifie tiperati.rs are trained in the fiunia- 

nientaiv nf welding practice. 1 Ins dei>artTnent was established at the request of the United States Government during the 

war, and trained many operators for war work before it was turned into '•nmmercial uses. 



52 



LESSONS IN ARC WELDING 



Automatic Welding 



'i'hf Lincoln IClectric Co. liave been wurking 
for some _\ears to develo]) a tin irouf^hly practical 
device for automatic welding. 

This takes the form of a carriaj^e which feeils 
the pieces to be welded under the electric arc and 
at the same time feeds down the electrode so that 
weldinij is continuous and is jiractically a me- 
chanical ])riicess. 



This process is onlv suitable where there is 
production work, that is, a number nf ])ieces of 
the same kind to be manufactured. 

Full j)articulars regarding this automatic webl- 
ing process can be had upon ap])lication and 
demonstration can be arranged for which will 
enable the ])rnspective purchaser to judge whether 
or not it will fulfill the re(|uiremcnts for his work. 



How to Use the Arc Welder 



The following sections on Design of Welded 
Joints and "Ten Lessons in Electric Welding'' 
are offered as an aid in acquiring the knowledge 
and skill necessary to make successful applica- 
tions of the electric arc welding jirocess. It would 
be imijossible to write any text book on this sub- 
ject which would include all of the things which 
it is necessary for an operator or engineer to 
know in order to always make a successful ap- 
plication of the process. The application of the 
process is a new science that has been explored 
in only a few of the directions in which it will 
eventually prove successful. The art of weklmg 
with an electric arc is like any other meclianicat 
art which may profitably be studied, but which 
only experience can perfect 

The manual training idea has been fulluwed 
out in the lessons on welding to a certain extent 
so that the operator may learn to weld by weld- 
ing according to definite instructions. 'Fhe oji- 
erator should follow the instructions to the best 
of his ability. It has been found by actual ex- 
perience that if the operator merely "])lays"with 
the apparatus and follows no definite plan dur- 
ing his training period, little is accomplished so 
far as the learning of the fundamental princi- 
ples involved is concerned. The operator must 
try to make the samples required in the lessons 



as good as possible, lly so doing, he will acquire 
a knowledge of the fundamental jirinciples in- 
volved in any welding application. It is impor- 
tant that the operator cut the welds as required 
in the lessons and criticise his own workmanship 
and allow other competent workmen to criticise 
it for him, so that in the end he will know be- 
\ond question whether or not he is making a 
weld while he is operating the arc. 

It will be found much cheaper in the long run 
to have the operator spend enough time to be- 
come thoroughly familiar with the fundamental 
]irinciples of welding during his training period 
than to put him on commercial work and allow 
liim to get his experience there. It should be 
thiiroughly understood that the operator will not 
be an expert bv any means when he has com- 
pleted the samples required in these lessons. It 
requires a large amount of experience to become 
:'n expert operator and owing to the rapidity 
with which the process and apparatus are being 
developed, it is impossible for one man to know 
all there is to be known about electric arc weld- 
ing. The operator should continually study ways 
of improving his practice and if possible study 
the practice which has been developed by other 
experienced ojierators. 



Design of Welded Joints 



b'roni an engineering point of view, every 
metallic joint whether it be riveted, bolted or 
v.elded, is designed to withstand a perfectly 
definite kind and amount of stress. An example 
of this is the longitudinal seam in the shell of 
a horizontal fire tube riveted boiler. This joint 
is designed for tension and steam tightness only 
and will not stand even a small amount of trans- 
verse bending stress without failure by leaking. 
If a joint performs the function for which it 



was designed and no more, its designer has ful- 
filled his responsibilities and it is a good joint 
economically. Regardless of how the joint is 
made the design of joint which costs the least 
to make and which at the same time performs 
the function required of it. with a reasonable 
factor of safety, is the perfect joint. 

The limitations of the several kinds of me- 
clianical and welded joints should be thoroughly 
understood. 



S3 



STRENGTH OT WTLUtU JOLMS 



A bcilted joint is expensive, is difficult to make 
steam or water pressure tight, but has the dis- 
tinguishing advantage that it can be disassembled 
without destruction. Bolted joints which are as 
strong as the pieces bolted together are usually 
unpracticablc, owing to their bulk. 

Riveted joints are less expensive to make than 
liolted joints but cannot be disassembled without 
destruction to the rivets. A riveted joint, sub- 
ject to bending stress sufficient to produce ap- 
l>reciable deformation, will not remain steam or 
water ]iressure light. Riveted juints can never 
be made as strong as the uriginal sections be- 
cause I if the metal punched ciul to form the rivet 
holes. 

There is no elasticity in either riveted, bolted 
or rmtogeniiusK- welded joints which nuist re- 
main steam or water pressure tight. Excess 
material is re<juired in the jointed sections of 
bolted or ri\eted joints owing to the weakness 
of the joints. 

AutogenousK- welded jnints have as a limit of 
tensile strength the tensile strength of cast metal 
of a conipositinn identical to that of the joined 
pieces. The limit of the allowable bending stress 
is also set b\ the properties of cast metal of the 
same com]i(isition ;is that of the joined pieces. 
The reason for tliis limitation is tliat on the 
margin of an autogenous weld afljacent to the 
pieces joined, the metal of the pieces was heated 
and cooled without change of comjiosition. 
\\'hate\-er proi)erties the original nu'tal had. due 
to heat or mechanical treatment, are removed by 
this action, which invariably occurs in an auto- 
genous welding process. Regar<lless of what 
phvsical jiroperties of the metal used to form the 
joint ma\- be. the strength or ability to resist 
l;ending of the joint, as a whole, cannot exceed 
the corresponding iirojierties of this metal in tlie 
margin of the weld. Thus assuming that an 
autiigenous weld be made in boiler |ilate, having 
a tensile strength of 62,000 lbs. .\ssume that 
nickel steel, having a tensile strength of 85.000 
lbs. be used to build up the joint. No advantage 
was gained by the excess 2,^,000 lbs. tensile 
strength of the nickel steel of the joint since the 
joint will fail at a point close to ('>2.0OO lbs. If 
appreciable bending stress be applied to the joint 
it will fail in the margin referred to above. 

The elastic limit of the built-in metal is the 
same as its ultimate strength for all practical 
purposes but the ultimate strength is above the 
elastic limit oi the joined sections in commer- 
cial structures. 



In spite of the limitations of the autogenously 
welded point referred to above it is possible and 
practicable to build up a joint in commercial steel 
which will successfully resist any stress which 
will be encountered in commercial work. The 
advantage lies in the built up structure and the 
inherent steam and water pressure tightness of 
a welded joint. 

The fundamental factor in the strength of a 
welded joint is the strength of the material 
added by the welding process. This factor cle- 
pends upon the nature of the stress applied. The 
metal added by the welding process, wdien sub- 
ject to tension, can be relied on in commercial 
practice to give a tensile strength of 45,000 lbs. 
jier square inch. This is an average condition: 
,i>>iuuing that the metal added was mild steel 
and that the operation was ])roperly done, the 
nietal will have approximately the same strength 
in com])ression as in tension. When a torsional 
stress is applied to a welded jouU the resultant 
stress is produced l:>y a combination of bending 
tension and comjiression, as well as shear. The 
resistance of the metal to shear may be figured 
at 8/10 its resistance to tensile stress. The 
metal added by the welding process, with the 
jiresent develo])ment in the art of welding, will 
stand very little bending stress. .\n autogen- 
ously welded joint luade by the electric arc 
process must be made stiffer than the adjacent 
sections in order that the bending shall not 
come in the joint. .\n electric weld, when prop- 
erly made, will be steam and water pressure 
tight so long as bending of members of the 
structure does not produce failure ctf the welded 
joint. 

Little is known at the jiresent time in regard 
to the resistance of an electrically welded joint 
to dynamic stress, but there is reason to believe 
that the resistance to this kind of stress is low. 
However, owing to the fact that in most struc- 
tures there is an opportunity for the members 
of the structure to flex and reduce the strain 
upon the weld, this inherent weakness of the 
welded joint does not interfere seriously with 
its usefulness. 

A few tests have been made of high frerjuency 
alternating stresses and it has been found that 
using the ordinary wire electrode the welded 
joints fails at a comparatively small number of 
alterations. This is of little importance in most 
structures since high frequency alternating stress 
i-. not often encountered. 



54 



ELECTRIC ARC WELDING 




Fig. 112 




Fig. 114 




Fig. 115 




Fig. 116 




Fig. 117 




Fig. 11 



Sfresscs iii Joints 

The dra\viii.s,^s rei)ro(iuced on pages 55. 5''). ^7, 
>lin\v several ty])ical metallic joints and the 
stresses which are hrought to hear on lliem. The 
method of welding is indicated. 

Tn iMg. 11_' it will he noted that a re-enlorcing 
plate is welded to the joint to make the joint 
sufficiently stiff to throw the liending outside the 
weld. 

Figure 113 shows a joint in straight tension. 
Since no transverse stress i.ccurs the heavy re- 
enforcing of Figure 112 is not required. Ju>t 
enough re-enforcing is given the joint to make 
up for the deficiency in tensile strength, of the 
metal of the weld. 

Figure 114 shows another method of huilding 
up a joint that is in straight tension. It should 
he noted that in both Figure 113 and F'igure 114 
as much re-enforcing is placed on one side of a 
center line thru the plates as is placed on the 
other. 

Figure 115 shows the original form of lap joint 
such as is used in riveting. The method shown 
f>'r welding this joint is the only method which 
can be used. It cannot be recommended because 
such a joint, when in straight tension, tends to 
bring the center line of the plate into coincidence 
with the center line of the stress. In so doing an 
excessive stress is placed on the welded material. 

Figure 116 shows the construction used in cer- 
tain tanks where a flanged head is backed into 
a cylindrical shell. The principal stress to be 
resisted by the welded joint is that tending to 
push the head out of the shell. The welding 
process indicated in the figure will successfully 
do this. Owing to the friction between the weld 
and the shell, the outer weld would be sufficient 
to hold the weld in place for ordinary pressure. 
For higher pressures the inside weld should be 
made in addition. 



55 



DESIGN OF WELDED JOINTS 




I'igjures 117 and 118 show another method of 
welding a flanged head to the cylindrical shell. 
These methods are preferable to the method in- 
dicated in Fignre 116. I^^igure 118 re])resents the 
recommended practice. 

i-'ignre 119 shows a plate and angle structure 
which miglit be used in shi]) construction. The 
particular feature to notice in the welding prac- 
tice indicated, is that the vertical plates do not 
reach the entire distance between the horizontal 
plates. This is merely a method of eliminating 
dit^cnlties in welding the ]ilates to the angle. 

l-'igures 1J0.\, 1201'., 1201) and 120C show a 
method of welding a crack in a locomotive 
frame. The object in this practice is to reduce 
the amount of metal deposite<l by the electric 
welding process. The metal of the jilate lami- 
nated structure is of better cpiality than the weld- 
ing ])rocess will deposit. And also a large 
amount of time is saved by this practice. The 
plates should be ■><< or 'j inch in thickness. In 
tnak'uuj uiiv tcr/(/, the siiutIIcsI aiinniiit of metal 
should be added b\ the welding process lehich 
is possible to add 7eitli perfect fnsion. 



Fig. i:o.\ 




Fig. 12(1B 




ELECTRIC ARC WELDING 







o 



o 



I'iK. i:i 







I'igure 121 sliuws a im'tluid (it welding a head 
into a cylindrical pi])*.'. Tlic thickness of the 
licad should l)e a])])roxiiiiately twice the thick- 
ntss of the wall of the pi]x'. The extra thickness 
plate is to gain sufficient stiffness in the head 
to make the stress on the well led material purely 
sliear. The jiressure from the inside tends to 
make the head assume a hemisplierical shape. 
This would place a bending stress on the welded 
material if the head were thin enough to give at 
llu- proper pressure. 



I'igure 122 shows a method of weMing a crack 
in a tire box sheet. The thin plate backing in- 
troduced at the weld makes the ojieration very 
much easier for the ojierator and jiroduce- the 
re-enforcing of the water side of the lire l>ox 
sheet which is must desirable. 



Fig. 122 



Data for Calculations 

I cu. inch of steel weighs .28 pounds. 

3.57 cu. inch of steel weighs i pound. 

One pound of 5 32 inch electrode may be de- 
posited in 27 minutes with 130 amp., 18 volts. 

25 to 30'^f of all electrode is wasted in "ends." 
15 ft. of 5 32 inch electrode weigh one pound. 
One K. W. H. of electric power will produce 
3413 B. T. U. of heat. 

On straight-away welding the ordinary operator 
with helper will actually weld 75'- of the 
time. 



57 



WELDhR PARIS 



No. 
1. 



10. 
11. 
12. 
1.'. 
14. 



No. 
1. 



S. 
9. 

lb. 
11. 
i:. 

13. 
14. 
15. 
16. 
17. 
IS. 
19. 
20. 
21. 
22. 



(D(9)(p(iD(lD |]®(8)©(li)®®®@|| (ipf)f)@@ 




n-a^t Cap, InrUT 

I lust Cap. Outer, .Mntor 

End 
.«,K,F. Bcarius! 
Insulating W'.i-iu-r 
Tube, P.rusli Hnl.icr 
C'innuitator Hai, .Motor 

End 
r.racket 

l;rU5h Iloldci. .M.il.r End 
Shaft 

^.'iimniutatnr C"ap 
Siirntk Collar 
Armature Coils 
Eye Bolt 
Sl.'itMr Eaniinali'Mi 



©©(ID® 



FIG. 123. DIRECT CURRENT SUPPLY 



No. 

15. 
16. 

17. 

IS. 



I'latne. Ki\ 
Pule (.oils, 
RIower 
I'i.-ld Coil~. 



et Tubes 
Motor End 



(lene!atnr End 



No. 

1''. 
20. 
21. 



.\rmature Lamination 
l-'rame Holt 
End Plate 
Mica Ring 



2i. 


Commutator Bar, 




Welder End 


24. 


Brush Holder, Welder 




End 


27. 


Clamping Washer 


2S. 


Kocker 


oq 


Felt 


M. 


Lock Nut Spring 


.^1 


Dust Cap. Generator End 


.1^ 


Lock Nut 


.^.1. 


Spring, Brush Holder 


.14. 


Finger Stud 


33. 


Finger 


fh. 


Brush 


37, 


r.lnwcr Support 




Krush 

Finger 

Shaft 

roninnitatur Cap 

Mica King 

Felt 

S.K.F. Bearing 

Lock Nut 

Dust Cap, Outer No, 

Lock Nut Spring 23 

Dust Cap, Inner 24 

Clamping Washer 

Insulating Washer 25, 

Rocker 26 

Brush Holder 27 

Commutator 28 

Bracket, Welder End 29 

End Plate. Welder End 

Armature Coils 30 

Field Coils 31 

Shrink Collar ^2 

Frame Bolt. Welder End 33 






FIG. 124. ALTERN.'^TING CURRENT SUPPLY 



Eye Bolt 

Frame Kiyet Tube, 

Welder End 
Blower 

End Plate, Motor End 
Stator Coils 
Frame Bolt, Motor End 
Frame Rivet Tube. Motor 

End 
Rotor Rods 
Rotor End Rings 
Frame Rings 
Shrink Collar. Motor End 



.\o. 
34. 
35. 
36. 
37. 
38. 
39. 
40. 
41. 
42. 
43. 
44. 



Bracket, Motor End 

Connecting Ring, Exciter 

Grease Cup 

Exciter Frame 

Poles 

Field Coils 

-Armature Coils. Exciter 

Mica Ring. Exciter 

Commutator. Exciter 

Brush Holder. Exciter 

Insulating Washers, 

Exciter 
Tube, Ernsli Flolder 



No. 

46. 
47. 
48. 
49. 

50. 

51. 

52. 
53. 
54. 

55. 
56. 
57. 
38. 
59. 
60. 

61. 
62. 
63. 
64. 
65. 
66. 



Clamping Washer 
Bracket, Exciter End 
Rocker. Exciter End 
Dust Cap 
S.K.F. Bearing. Exciter 

End 

Dust Cap, Exciter End 
Insulation 
Exciter Shaft 
Terminal Block, Exciter 

End 
Pig Tail Clip 
Dust Cap, Motor End 
Connecting Pin 
Lock Washer. Motor End 
S.K.F. Bearing 
Dust Cap, Inner, Motor 

End 
Felt 

Spring, Brush Holder 
Connectors 
Stud. Finger 
Connecting Ring 
Blower Support 



58 



niiuiiiiiiUitiJii imui jtoiiii uonniirr nimnnniiiinnuu ru 



TEN LESSONS IN ARC WELDING 




t'iayiain •:>[ Electrical Connections of Lii 
and \'olt-Anipere Characteristic 



..In Aw Wcl.Jc 



(A) Electrode Holder 

(B) Series Field (ditTc-r. 
connection) 



■lUia! 



(C) 


Exciter Shunt Field 


(G) 


Ground Plate 


(D) 


Diverter Resistance 


(P) 


Separately FJxcited Field 


(K) 


Exciter 


(R) 


Rlie.ist.it 



(S) Stabilizer 

(\V) Welding Generator 



LESSON I 



The .-lie Jf'cldniir Machine 

It i-' iniportaiit tint the operator bccoiiK' familiar 
witli the \vul(lin!4 iiiacliiiie lufurc attcmiitiiit; t.i ii>c 
tlie arc inr welditit; operatiuiis. Two drawings arc 
rtproduceil sliow ing tlic iiamc-s of parts of the wtddtr 
fit. It is not necessary for the operator to ineniorizc 
tlie names of the detail parts except that he should 
understand the location and purpose of the essential 
parts as follows: — P.rush, Brushholder, Commutator, 
Exciter Commutator, Field Coils, Motor. Exciter, 
(Urease Cup, Ball Hearings. Shaft, Bracket, Frame. 
Poles. (See page ,^8.) Any electrician can point out 
these parts on the welder set if the operator is unable 
to do so. 

The arc welding generator is electrically separate 
from the motor which drives it. .\ welding generator 
may he driven by either a direct current motor or an 
fdternating current motor or liy a steain or gasoline 
engine. The source of power to drive the welding 
generator has nothing whatever to do with the be- 
havior of the welding generator provided, of course, 
ii is furnished in sutficient quantity and turns the weld- 
ing generator at the jiroper speed. The motor end of 
the welding machine is like any other motor of the 
same rating. 

The principle of operation of the welding generator 
is very simple to the man who has had some experi- 



ence with direct current gcneratcirs but is dittictdt for 
:>ny one else t> luiderstand. I'Hr the lienelit of the 
man ubo has had electrical e\|Krience. it is sul^'icient 
to stale that the welding generatiT is merely a specially 
designed, sep.irately excited generator with a differen- 
tial ciimpiamd winding and that an inductive ballast is 
f-ed in the arc circuit. It is desirable for the operator 
to understand the principle of operation of the welding 
set as well as the electrician imderstands it but it is not 
abschitely neress.ary. The accnmpanv ing cut sliows the 
volt-ampere characteristic and the wiring diagram of 
the wilding generator. 

The welding oiittit should always be installed by an 
electrician. All cables are labeled and the direction of 
r'tation is marked so that no difficulty will be exinri- 
enced in installing the outlit without the use of a wir- 
ing diagram. 

The St.abilizer is made up of coils of wire arMiind 
a laminated steel core and its purpose is to make the 
arc steady and easy to operate. 

.\n electrician should explain to the operate 'r the 
proper method of starting the outfit. 

The control panel contains the apparatus with which 
the operator controls the behavior of the welding gen- 
erator, adjusting it to give the i)ropcr amount of heat 
lor welding. Two cuts are shown showing two types 



59 



TEN LESSONS IN ARC WELDING 



of contriil i>anfl used. The portaKle t>pe accomplishes 
the 'ame thins as the stationary type. 

I-ig. 128 shows tlie ordinary equipment used by the 
operator, and wehJing tahle. Referring to Fig. 140. tlie 
proper clothing for an operator is shuun.— it consists 
of black c.-iip, unidualls, cotton s^untlet gb>ves. split 
leather apron. 



Ad]iist})icut of Machine 

1 wpen main switcli :uid cntrnl ^witch nn i)anel. 

2, Start welchng set. 

.V Turn rheostat as far a> it will go t.) the left. 

4, Close control switch into position markt-il UX). 

(In this position the current in the arc will be approxi- 
mately 1(X) amperes. ) 

^. i'ut a piece of ,,■■/' \ielding wire in the metal elec- 
trode Ii.ilder. 

<> Place ,1 piece of boiler plate scr.ip on uchling 
t.ible !i' practice on, 

", Close main switch on panel. 

8. Sit down on .stool in front .if welduig t.dile. 
Take hand shield in left hand, metal electrode holder 
in right hand. With shield held in front of face touch 
b'.iler plate with end of welding wire. The re-idt will 
bi- a 'i.ark and the welding wire will stick to the boiler 
plate. Let go of electrode holder and open main swNtch 
oi^ p.'inel. 

''. With a new piece of welding svire. and face shield 
in front of face, scratch welding wire sidewise on 
boiler plate t.i get sprak. then draw welding wire about 
an eighth of an inch away from the plate. Hold webl- 
ing wire vertical to boiler iilate, r.tberwi^e arc wdl be 
difficult to st.irl. 

Repeat the above operation until an arc can be main- 
tained as long as desirable. The beginner should burn 
from "5 to K.K) pieces of welding wire at this practice. 
obser\iiig through the shield what happens in the arc. 
.\s the o|ierator becomes m.ire skillful he sboulil try to 
hold a shorter arc. The proper length is about an eighth 
of an inch. The operator should spend about 15 hours 
on this kind of practice. The ,i mount of current or 
amiieres re(|uired for welding depemls pnnci[iall.\ up. in 
the size welding wire used. Three-sixteenths inch 
welding wire require^ about l.SO amperes. (Turn rheo- 
stat as far to left as it will go and close contnd switch 
into 1.^0 ampere i,.>Mti.>n,) l-..r points in between I'lll 
and 150 ampere- turn rheost.it t.> risbt with contr..| 
switch in 150 ainiiere p..sition. 



Ammeter 




.M.lin Switch 



\'..ltnR-te 



Klieostat 




eoiitn.l Switch 



Fig. 1J6. Stati.iii;iry r.incl. 




Fig, 1J7. I'.jil.ilil,. P.Tiiel 




Fig. 138. Operator's Tools 



60 



TEN LESSONS IN ARC WELDING 



LESSON II 

Starting the Arc 



This exercise deals with the proper metlmd cit 
starting and stt)pping an electric arc. The lieKinner 
ll^^,■llI.v draws an arc and starts to weld at whatcvir 
point the arc happens to start operating properly. In 
other words, the beginner usually welds where it is 
possible lor him to weld rather than welding in a pre- 
determined place. The purpose of this exercise is to 
give the operator suHicici.t contriil of tiie arc to cii- 
alile him to weld at any place he may decide upon. 

1. Place a piece of scrap boiler plate on the welding 
t.ilile, \\ ith a piece of soap stone mark a line acrl)^s 
tlie plate. Now weld a bead as nearly as possible ] /' 
to the right of this line. Make the bead as straight 
as possible. Repeat tbi^ operation until a perfectl\ 
straight bead ' j" from tlie iiredeterniined line can be 
laid down. 

2. In this exercise the operator shoidil print hi^ 
initials on a piece of scrap boiler plate and weld a 
bead over the lines. Having produced a perfect set of 
initials in this maimer take another piece of scrap 
boiler plate and make the initials the same size with- 
out previously printing them witli soap stone. This 
operation should be re]ie.ite<l until the operator cm 
reprtiduce his initials without following the lines. Tlic 
purpose of this exercise is to train the operator |o 
Control an arc and lead it in a iiredeterniined direction. 
It also involves the training of the operator's eyes to 
see where he is leading the arc. This will be difficult 
at first owing to the fact that the operator can see 
nothing but the arc itself through the protective gla^s. 

3. The operator shoulil now take hannner and chisel 
and examine the beginning of several beads wliich he 
has made. It will be found that the beginning of the 
liead is usually not securely welded to the plate. This 
is due to the fact that the are was held too long at 
the instant the bead was started. The operation of 
starting the arc at the predetermined point should be 
repeated with this fact in view until a satisfactory weld 
is made at the begimiing of the liead. 

4. The end of the bead is quite as important as its 
beginning. In referring to lieads which the beginner 
has previously made it will be found that a consider- 
able crater has been left at the point at which the arc 
was broken. The objection to this crater is th.at it is 
difficult to start welding at tliis point when it is de- 
sirable to continue the bead. The crater may be filleil 
before the arc is fully broken by merely crowding 
down the arc until the desired amount of metal is 



added, and breaking the are suddenly by pulling the 
wire sharply to one side. The operator should practice 
this operation until he is able to finish a bead leaving 
a crater of not to exceed i'.-. of an inch in diameter. 

5. The exercises outlined, in the preceding four 
|)aragraphs should occuiiy at least ten hours of the 
operator's time. The following sample is to be made 
a- to the record of the operator's ability to start and 
slop an arc properlj : 

Materi.al required: One \ 2" s.\2" :<.]/>" piece of boiler 
plate; three sizes of electrode are required — h", i'2", 
,'s". 

Xo marking with soap stone is to be done on the 
I'late. Referring to the photograph reproduced here- 
with, the lirst three rows of lieads are to be made 
uitli 1'.." wire using approximately 150 amperes. Kach 
bead should be one inch long. The beads should be 
lhree-(|uarters of an inch apart. They should be 
straight and parallel. Kach bead should have a per- 
fect weld at its start and a \ery small crater at the 
tiuish. The next live beads are to be made using ;i'j" 
eUctrode and the next two, \ising Jg" electrode with 
about 140 and I0(j amperes respectively. One side of 
the place should be com])letely welded in accordance 
with the above instructions. The plate should then 
be turned over and the operation repeated and lier- 
feeled on the other side of the plate. 




\\x\:-'- 




lie l-'y 



61 



tt H u n n Hf Hi D K n it 



TEN LESSONS IN ARC WELDING 



LESSO.X III 

Building Lp> Opodtioii 



The purpose nf tliii oxerci-e is tn show the oiicratur 
the iirripor nielhud (if luiildiivo up several layers of 
welded material. It is asMimed tluit in Lessiin II the 
operator has learned to deposit metal from the welding 
wire em a pieee of boiler plate and have it entirely 
welded along the line of fusion. L'ntil the operations 
outlined in Le-son II arc e'omplctely mastered, it is 
ll.^eless to priieeed with the e.xercisc of bnilditig-np 
opi'ration>. 

Material reipiired: One 10".xl2".\' j" jiitee of hoikr 
plated. ( Ine size i.if elertrode, ..L of an inch, is reonired 
The enrrent vlmnld lie ahont 14tl amperes. 

Keferrin.g to tile photograph rf|iroihieed hereuilh. 
three p.ads are to lie hiiilt np .m the fare of tin- plate. 
These pads are to he (>" long. 1" widr. 1" high. T' o 
hrst pad starting from the left hand side of the jd.i'e 
i- til he hnilt up without .'iny particular design or p.it- 
tcrn, and without hnishing or clciuing of tlie o.\idr- 
covercd surfaces. 



away any metal to knock the oxide from the top of 
the layer with a cliisel. The wire brush may be nsed 
to brnsh the oxide off the metal after it has been cut 
away with a chisel. 

The operator has now completed three pads. The 
tiist pad illu-trates how wcldin.g shoidd not lie done. 
The second pad illustrates a fairly satisfactory practice. 
The third pad illustrates the liest practice. If possible 
the oiierator should ha\e this sample sawed diagonally 
through the three p.ids. It should then he set up em a 
grinrling maeliiur and a line sm-facr gnnnid on the 
cut section of the I'ads. This can be done in a tool 
loom. The ground surface should then be p.iinted 
with diluted sulphuric acid or tincture of iodine. It 
wdl then be easy to compare the (|nality of the metal 
in the three pads. The ojierator should al-ei observe 
carefully thr line of fusion between the pads and the 
origin.il iilatc This fusion must be perfect if the weld 
is of any \alue. The idiotoyraiili reproduced herewith 
illnstr.ates the .ippe.'irance of a good line of fusion. 



The next pad is to be built up following the defmile 
pattern, hirst, brush the snot mi which the second ii.id 
is to be bmll \er>' thoroughly with a wire brush. 
Second, build up a single Layer of niet.il the width of 
tlic pad Using a series of beads laid along the o" 
dimension, always starting at one end and tini-hiiiu; at 
the other eml. H,i\ ing deposited the lirst layer, the 
oxide coxcred surfaces must be brushed tliorongliU- 
with a wire brush. Kacli layer should be brushed ;.t 
least tliree minutes. The second layer of the pad should 
be built up so that the beails run at right angles to the 
beads of the lirst l.i\er, i. ,-.. the lu^ads are par,dlel 
to the 2" dimension of the pad. This practice is com- 
monly called "lacing." The second layer to be as 
thoroughly brushed as is reipiired upon hnisliing the 
lust la\ir. Each succeeding layer should he thoroughly 
1 rushed. 

The tliird pad is to be built up in exactly the same 
manner as the second pad with the exception that in 
place of brushin.g the work with the wire brush only 
between e.icb layer, the oxide mu-t be entirel\" cleaned, 
off by the Use of the hammer and chisel. It will be 
noted that the oxide may be remosed b}- com|iaratively 
light blows on the chisel. It is not iiecessar\- to cut 





Fig. 131 



62 



TEN LESSONS IN ARC WELDINCJ 



LESSON IF 

Plate JFeldiug 



This exercise is one oi the m.i-.t imiMirtaiit nf the 
scries because t'-.e welding "f plate i^ tlie nmst frei|iuiit 
application of the electric arc uchliiiK process. Tli<- 
welds which must he made in structures made of jilate. 
such as tanks, are not always hnriznutal, so tliat the 
o|)erator must learn to weld not c>n1\ in the liorizontal 
position hut also in the vertical and overhead positions. 
Three saniides are to he made as the record of tin- 
operator's ability to weld in the horizontal positinu 
and tile vertical and straight overhead positions. 

Material leipiired: Si.x l()"xl2"x'.i" pieces of h'lihr 
plate lieveled 45 degrees on one \2" edge. r.>" electrode 
with l-in t'l 150 amperes. 

1. Tlie operator should spend approximately ten 
luuirs in preliminary practice. .Several pie.'es of scrap 
boiler plate should be beveled and tacked together as 
shown in the accompanying photograph. These plates 
sliould then lie set up vertically and welded, starting 
at the bottom and welding up. The operator should 
use his i.wn re^' lurccfulness in arriving at the be^t 
way to make a weld in this position, trying several 
ditiferent methods and observing the following points; 
Does the weld extend compIetel\ from the inner to 
the outer edge of the plate? Does the heating of the 
plate cause sufficient expansion and contraction to 
affect the character of the weld' Does the expansion 
and contraction caused by the heating of the pla'.c 
produce war|iing or buckling? .After the oper.itor has 
satisfied himself on these points two pieces of scrap 
boiler plate should be beveled and placed in position 
ready to weld straight overhead, and the operator 
should try to weld them together in this position. 
welding from the underside only. The oi)erator should 
put the pieces approximately one-sixteenth of an inch 
apart for this exercise. This kind of welding is \er\ 
ditlicult and requires a considerable amount of practice 
to master. It will be found that the operation will be 
somewhat easier if 150 amperes is used on .:'.:" elec- 
trode at first. In welding beveled plates the o|)erator 
should remember that the welding wire or electrode 
should be held as nearly perpendicular to the surface 
being welded as possible, and that good '.cridiiiii can 
unly be accoinpUsIwd xclicn a sliori urc is iiuiiiilaini-tl. 
The operator should pay particular attention to ihe 
dilference in sound between a long and a short our. 
A long arc sputters and has a distinct hissing sound. 
It is iiTipossihle to weld with such an arc. .-X short 
arc has a rapid fire metallic click which may be readil\ 
distinguished. The operator should maintain a short 
arc on all classes of welding. \\ here jiossible an elec- 
trician should be asked to connect a low reading volt 
meter across the arc so that the voltage may be read 
while the operator is welding. The volt meter -luniM 
Had from 15 to 18 volts while the arc is in operation. 
The greatest amount of heat is obtained on the work 
wdien the electrode holder is negative. This is the 
proper connection for both metal and carlion electrode 
work. 



While the arc is in operation thire will be ,i circular 
spot of molten metal upon the work. The fiperator 
should concentrate his attention upon the siile of this 
molten spot of met.d which is in the direction of 
motion of the electrode. This may also be described 
as the forward edge of the circular spot. The arc 
should he directed on this point, since it is at this 
point that the greatest amount of heat is desirable. /( 
13 ['ossibli- In iniil;c an clciti-ii nrld oiilv r>7.'r;i llw 
ijlohutc of ninllcn iiirlal from tlic -ictditig :>.-irc is 
throzcii into iiioltrii iiirlal on the /'ii'cc Iwing jc.'/rfci/. 




Fit'. 13:. Tacke.i Plates 








log. \ii. Ilmiz.iiilal \irncal and IKcrlicail S.ini|.lcs. 



63 



TEN LESSONS IN ARC WELDING 



If tliL- nlii|)uK' iif motal lII•cl|p^ iin imtal which i> <i>'i 
Tiuiltcn it may --tiik 1)UI it will not ho wt-lded. TIil- 
operator slmiilil stiuly the actimi of tlu" metal in the 
heat of tlie arc \ ery carefully. The operator shouM 
bci;in to reali/c at thi-- point that merely holding an 
arc is not neces^arily wcldiiisi Init that the art of weld- 
ing is ninety per cent l.rain v\ork and ten per cent 
n'anual lahor. 

2, I'lace the horizontal ^aniph- of uildinn in posi- 
tion ..n the welding tahle. I'lU a ;'_■" electrode nnder 
each plate in a ]iosition parallel |o the heveled edges 
and ahoiit '_■" front the lower edge of the bevel. This 
will raise the heveled edges higher than the S(|nare 
edges and gi\e the sample a ridge through the center. 
Tlie oliject of this practice is to allow for the warping 
of the jilates liy the heating r,f the arc. -\fter the 
■•ample is welclccl it should he straight with the two 
plate- s(iuarely in line. Place the edges 's of an inch 
a|iart all the way across. Tack the pieces together as 
shown in hig. l.ii. Xow with HO amperes .and a 32" 
electrode, weld (■ne layer in the liottom of the lie\el 
in about 3" seclion^. I'.y this is meant that the o|iorator 
should weld three inclu's. skip three inchs, webl three 
inches, skip, etc.. until he h.is gone .all c.f the wav across 
the i)late. then go acros^ the plate ag.iin. tiljing the 
three-inch gaji-. This is to minimize the effect of the 
healing. The plate will then be welde.l with one layer 
all the ua\ acr. iss. The operator nnist manipulate the 
arc in such ,1 maimer .as to weld tin' lower edges of the 
plate com|iletely together, i. ,-.. the met.il from the 
el.'Ctrode must run clear through the plates and be 
firiuly welded on the edges. The operatcjr should then 
take hammer .and chisil .mil clean the oNide from the 
surface of the .velded metal ver> thoroughly. The 
.second layer may now be welded into the l)e\el start- 
ing at one eiul and linishing at the otlur end. This 
layer should be thin and should n.)t extend higher 
than the ipiper surface of the plates, fliip oxirle from 
surface of welded material ,ind put the third and fin- 
ishing layer i.n the weld. The third laver should ex- 
tend about 1',; of an inch beyond the edge of the bevel 
on each plate, and ',s" above the ujipcr plate surfaces. 

I he rdate shouM now be turned o\er and a re-enforce- 
nient of equal width and thickness put on the other 
side. The pnrpo-e of this practice is to make the sec- 
tion of the weld upial on both sidi-s of a center line 
through the metal of the plate. If the weld were re- 
enforced on one side and not on the other the stress 
would be concentrated on the side which was not re- 
enforcetl when the weld is put in tension. 

3. The tw.. plates sh.iuld be tacked together as in 
tn-st exercise but in this case the beveled edges are to 
he set vertical, as shown in b'ig. 134. The weld is 
to he made according to a dehnite pattern starting 
at the bottom and finishing at the top. This jiattern 
i.s tnangul.ar. The operator should start on the right 
hand plate at a point about j',: of an inch to the right 
of the beveled edge, holding the welding wire as nearly 
jierpendicular as possible to the surface being welded. 
1 he nvivemcnt should be along the beveled edge of the 
right band plate toward the farther edge, tlien along 
the beveled edge of the left hand plate toward the 
nearer edge, extending to a jioint A of an inch to 
the left of the bevel on the left hand plate, then across 
to the starting point. Five-thirtv-second electrode with 
about 125 amperes is to be used. The operator must 
pay particular attention to see that the farther edges 
of the plates are securely welded together. A consid- 




er. ihle amount oi metal should be niii through the 
edges to make tlii^ ciTtaiu. 

4. b"or the sample ui ■■\erhead welding, the plates 
ma> he tacked together .as shown previously except 
tli.it the opening should be approximately ''4 of an 
inch. The two jilates are to be \velde<l in the over- 
head position after they have been tacked. Several 
pieces of plate ' s of an inch thick. I'l" wide and ()" 
long are to he cut. and a .i'j" electrode should be stuck 
on extreme edge of one of the corners so that the 
electrode stands out jierpeud'cular to the piece. The 
purpose of the electrode is to serve as a handle. This 
!s" piece is to be pushed through quarter inch opening 
between the plates front the under side and to be 
brought into position so that it will fcjrm a backing 
for the weld. big. 133 shows the position of this 
plate. .After the |)late has been placeil in ])osition it 
may be tacked. The use of this plate makes the 
overhead welding somewhat easier than welding with- 
out its use ."^tart tlu- overhead weld at the center of 
the job and weld toward one end. A definite pattern 
should he followed. Start at the lower ed.ge of the 
right hand plate at a jioint 1'.; of .an inch to the right 
of the bevel. Continue along the beveled edge of the 
right hand plate up to the backing plate, across the 
backing plate and down the beveled edge of the left 
hand plate to a point o; of an inch to the left of the 
bevel. This will form the first head. .Vow start the 
second bead at the beveled edge of the right hand 
plate and on top of the first bead, and fill in, as far 
.!« possible, the opening formed Ijy the heveled edges of 
the plates. .\ third bead will be required to complete 
this operation. The operator now has two surface^ 
to weld on, the surface formed by the welding ma- 
terial, which should be appro.ximately vertical, and the 
surfaces of the plates to be welded. The pattern of 
the lirst pad should be followed out from this point 
on welding at the junction of the previously welded 
material, and the surfaces of the plates being welded 
tot;ether ~o far as this is possible. This inakes the 
weld more a \ertical weld than an overhead weld and 
cemsiderably sim|)lihes the operation. The operator 
should use about 151) amperes to start with, cutting 
it down to 125 or less as the plate warms up. Having 
cemipleted one end <.if the weld in this manner the other 
end may be welded in exactly the same way. It will 
be found that the backing plate will warp and tend to 
get out of contact with the be\eled plates. This will 
not interfere with the welding and will enable the 
ojierator to rc-enforce the weld on the top side, which 
i- \er\ desirable. 



04 



TEN LESSONS IN ARC WEI,I)1N(; 



LESSOX V 

'I'liiii Plate It'cldiii^r 



I lii^ iNcrriso is tn ,;;i\e the MpiTatur ^utiu- i-\|iii inuc 
mi thin plate wi-liling. Tlie difficiiltics ciicnuiiti-rt-il in 
thin phitc welding are comparatively simple of solution, 
and the nperator is left to use his own resources to a 
considerahle extent in making the sample. The great 
difficulty in welding thin plate arises from the tendency 
nf the arc hi hurn through the thin plate Dwing to the 
great intensity of heat. Practically all thin plate is 
covered with a heavy scale of hlue oxide, .nid il is 
necessary to get this oxide cleaned off in order tn 
make a good weld. This may be done with hammer 
and chisel or a sand blast. The operator has alread\ 
found tluit it is necessary to have cle.an metal in order 
to make a good weld. The quickest and best uay nf 
getting clean metal is to sandblast the surfaces tn be 
welded. This aiiplies to metal of all thicknesses. The 
reason Iilue oxide gives the operator trnnble is that it 
is a very poor coiiductnr of electricity, and it is hard 
to get the arc started on an oxide-covered surface .-inrl 
also that the oxide gets into the metal of the weld. 

-Material required: One piece of 24"x.^(l" sheet -tei-l 
approximately i^e of an inch in thickness; 'n" electrode 
with M to 90 amperes. 

1. The operator should stiuK the drawing repro- 
duced .111 |iage 66 (big. l.v l and l.iy out the |neces to be 



cut in order lo make the sand blast pot shown. This 
will lea\e some scrap material .iround the edges which 
should be cut with a hack saw into pieces approximately 
i"x4". The operator sbonM practice welding these 
scrap pieces by laying them <lou n on the welding tabic 
.ind welding a straight seam. ( )ne sample should also 
he welded with the two pieces perpendicular to each 
other as shown in accompanying cut. il'ig. 135.) .\l>- 
proximately two hours should be spent on this practice. 

2. The operator shoubl n..\\ 
cut the plates necessary to form 
the sand lilast pot and weli! them 
together. It is suggested th.it the 
heads be made smaller th.in the 
shell so that they fit on tlu' inside. 
They should set back from the 
edge of the shell about ' i". ( )ne 
small hole should he burned 
througli at the loc.'iliou of one of 
the fittings in order to allow the 
heated air to escape while the 
welding is being done. The litting 
can be |iut on the sand Idast pot at 
Some later time h\' the operator. 




Fig. 1,Vi 



LESSON ri 

Pressure JPeldiiio- 



Th 



exercise is in the n.iture of a test cif the ability 
ol the operator to make a solid homogeneous weld 
which is ]iroperly anrl thoroughly done. .\ great many 
electric welds are subjected to steam or water iiressure 
and unless they are properly made they will show leaks. 
and will fail at a point below the i)ressure for whicli 
they were designed. It is \ ery important that the op- 
erator should know when he is making a good weld. 
]f he does not know this his work is entirely worth- 
less. He is as poor a workman as the jeweler who 
must smash an expensive watch in order to find out 
how it was made. .\ skillful e)peeator. who h,as a 
reasonable degree of judgment and intelligence. kno\\s 
when he is making a good weld. If he has made a 
section of a weld which is not good, he should eitliir 
cut that section out and reweld it or inform the man 
responsible for the job of the fact that a i)articular 
section is faiiltv. -\ man who will lie to Iiimself in 
regard to the ([uality of his work, will lie to the man 
wlii> is responsible for its quality, and is worse th.in 
worthless as a skilled operator. 

-Materi.il recpiired : One 18" section of 8" wrought 
it on pipe or seamless steel tubing, two .'>,s" thick boiler 
plate heads to fit on the inside of the pipe or tube. 
These heads should be beveled 45 degrees on the cir- 
cumference, 6 pieces of I" black wrought iron pipe o" 
long, one piece of .\^" or 1" pipe according lo the sixe 
water pipe used in the shop wliere the welding is done. 
This pipe is to lie connected to the water system so 
that the completed sample may he tested under pres- 
sure. Six holes are to be drilled at interv.als of 2" 
into the 8" pipe to take the six 1" pipe. One hole is 
to be cut to take the 34" or 1" pipe. 

1. The heads are to he welded into the jiipe as 
shown in the accompanying cut. (Fig. 13o. ) The op- 
erator must be careful to hold a short arc and so far as 
possible keep the electrode perpendicular to the surface 
being welded. The surfaces wdiich are to be welded 



must be clean and the o\ide must be reiiio\ ed from 
e.ieh layer of metal before the next layer is welded, 
b\ the use of sand blast or hammer and chisel. The 
1" pipes are spaced close emaigli together so that some 
dif'ticnity will be experienced in makin.g a good weld 
between pipes. This is done purposely because it is a 
difficulty frequently encountered in practice. The op- 
er.ator should mark witli chalk the spots where he 
belie\es. owing to the manner in which he welded the 
sample, that the leaks will occur. Weld the ends of 
the six 1" pipes shut. 

-'. The oiierator should connect the sample to tlie 
water system of the shop and test it for leakage. (It is 
advisable to pour the sample full of water before the 
connection is made so that it will be entirely filled with 
water when under pressure.) If leaks arc found the 
operator should cut out that part of the weld, e.xainine 
the weld and find if possilile the cause of the leak. 
The rlefectixe spots sliould be rewelded .and the test 
1 ejieated. 




Fig. 136 



TEN LESSONS IN ARC WELDING 



NORSE: 2 TAPER 




NOZZLE 



i"?IPE NIPPLE-^ "Lb ?! ly L 



r\ 4: COUPLING 



I'lK- 137. Sand l;l..H r.'t M.iac by Arc W.l.liiii;. 



66 



TEN LESSONS IN ARC WELDLNG 



LESSOuN rii 

^ lisceUan eo us Jo bs 



The (iliicct of this cxercisf is tn .nivc tin- (ipcialor 
an idt-a .)t a few of tlie many (litTcirnt kinds of ap- 
plications of tlie process. A ^rcat deal depends npon 
the <i[icrator's natural resnnrcofidncss in planning a 
jnh. ( )ne of the difficulties i^ in knowini; liow tei j>o 
about a joh so that it may lie done with the least pos- 
sible exertion. The more highly skilleil the operator 
is. the easier will be the way which he choc.ses to per- 
form the operation. This involves careful planning of 
the operation before it is started. The operator who 
cannot pl.m in advance exactly how he is going to do 
the joh will liave little success in doing it. .Xs has been 
stated liefiTc. success in welding depends more upon 
the use of the brain than upon tlie use of tlic h.inds. 
The operator should lie able to tell exactl\ liow he 
proposes to do a certain joh and explain the reasons 
why lie intends to do the job in that particular way. 

Material required: fine riveted section .as shown in 
Fig. Lis, line angle iron section as shown in l-'ig. 139. 
These two s.amples need not conform tei any specified 
din^e^^ions. 

1. h'or prelminary practice the operator should take 
two pitcrv of '4" scra|i boiler plate, and tack them to- 
gether ni the fi>rm of a lap joint. This sample should 
then lie set up iu the vertical position and a fillet 
welded on the underside of the lap. simil.ir to big. US. 
This ojieratiou should be repeated until the operator is 
able to git a good weld and the fillet ha^ .1 uniform 
appearance. The opcrateir should calculate tlie number 
of feet per hour of this work he can do. This work 
is similar to the operation encountered in the webling 
of a caulking edge on the riveted seam of a steam 
boiler. It is necessary to w'eld only one bead to form 
the fillet; 140 to 150 amperes should be used. The 
operator should cut across the seam and examine the 
fillet to determine wdiether or not he has made a 
geioil Willi. 

2. With a piece of scrap boiler plate set in the 
vertical position the operator should weld a mimber 
of circular beads approximately I'j" in diameter. 
.\fter 8 or 10 of these circular beads have been welded 
the operator should clean the o.xide from the surfaces 
and weld a second bead around the first bead. This 
is an operation similar to that of welding around the 
head of a rivet. One i>f these circles should be cut .and 
the weld examined to see that it has lieen properly 
done ,ind that the second bead is fuseil thoroughly to 
the plate and to the first bead. This is an operation 
which must be thoroughly mastered before iirocecdiug 
further. 

3. This exercise consists of welding two pieces of 
heavy plate together withtmt bevelin,g. If ])ossible two 



|)ieces of \s" thickness boiler plate should be obt.iincd 
for the exercise. Kach edge which is to be welded 
siK.uld be set in .1 horizontal position and a bead 
welded along the center of the |)late. The second 
bead shoiilil then be welded in top of the first, remeiv- 
ing the oxide from the first before the second is .ip- 
Iilied. When both edges are thus prepared and put 
together the operator will have -what amounts to 
beveled edges to weld together, but it will be neces- 
sary to weld from both sides in order to eomiilete the 
jeib. One weld of this nature should be made and cut 
so that the o|ierator ni.iy examine it to see that fu-ion 
has taken [dace throughout the entire weld. 

4 This exercise is the one shown in the cut (Fig. 
13S) and consi-ts of welding the caulking edge of a 
ri\eteil joint .ukI welding around the rivet head. The 
method of welding the caulking edge has been pre- 
viously explained. In welding around the rivet head 
it is advisable to heat the rivet before welding around 
the head. With the plate iu a vertical position (rivets 
above the caulking edge), draw an arc on the head of 
the first rivet, allowing the metal from the electrode 
to fall clear of the rivet head. This should be con- 
tained for about fwci minutes or until the rivet is 




Fig. I. IS 



67 



TEN LESSONS IN ARC WELDING 



tlinrniii^bl} liiated. tlun tlu- tilk-t '-huuld be ui-Idcil 
around tlie rivet. The operator should then skip two 
rivets and repeat the operation on the fourth rivet. 
Tlie idea of skippiui; is ti. keep the heat distributed 




Fig. 139 

.■^n that eontraetion in the tnet.d wdl not set up sliear- 
ing stresses in the rivets. ]'\ lollouini; the aliove 
practice a very tight joint will result wlien the metal 



of the ri\ ets and plates couls. The result is similar 
to the result obtained li\ luutin;,' in a hot rivet and 
peening it over. W hen sueh a ri\et cools it contracts 
and pulls the plates tightly together. The operator 
may turn the sample over and repeat the operation on 
the other side. perfectiuL; it if possible. 

5. The exercise of welding an angle iron section is 
jup which illustrates a type of job which is quite com- 
mon. The angle may be cut from a straight ani^le 
section and the triangular sha]ie cut out with a hack 
s;.w. The triangle is cut out ^o that the .angle may 
be bent at right angles. The tip of the triangular, 
however, must be cut sipiare olf in order to allow a 
right an.gle Ui be bent without the edges coming en- 
tirely together. The clistance between the edges after 
the an.gle has been bent through 90 degrees should be 
einial to the thickness of the angle. The operator may 
then bridge cross the two edges from one side allowing 
a- little metal to drop down between the edges as pos- 
sible. TImi the angle shoiMd be turned over and the 
space between the edges completely fdled b\ welding 
in one or more lavers. 



LESSOA nil 

Fine Weld I lis 



This exercise deals with the welding of lines into 
the llui- sheet of a boiler. This work is encountered 
in fire tul)e boilers of all kimls. The oper.ation re- 
quires a considerable ammuit of skill in handling the 
arc. .X preparation of the flue sheet for welding in 
actual practice is usually what makes the job a success 
or failure. In practice the proper way of preparing a 
flue sheet for welding is to put the Hues in exactly as 
if thr\ were not to be welded. Tin boiler shoulrl 
then be fired at least once to allow the tubes to take 




Fig. 140 



ibeir permanent set. The due sheet shoidd then be 
sand blasted to clean tile surfaces to be welded. If 
no san<I blast is a\ailable the pnenm.itic tool should 
be used to knock the oxide off the surfaces, after 
which the surfaces should he thoroughly brushed with 
;i wire brush, then the welding may be done. If the 
work is prepared in this manner and properly welded 
the results will be uniformly successful. 

Material nquired : .Section of ' /' boiler plate with 
four 2" Hues rolled in as shown in cut; ' «" electrode 
with 90 to 115 amperes should Ije used. 

I. -Set the sample as shown in the photi>graph. Use 
head shielcl and hold the electrode holder in both hands 
as shown in the cut. The first due .it the top should 
be welded starting at the point shouu in the cut and 
welding one-half way around, moving fnun right to 
left. Then the other one-half welded st.irting at the 
eiriginal point and moving downward to the left. The 
second flue should then be welded starting at the bot- 
tom and welding in two halves so that they meet at the 
toji. The operator may then weld the other two flues 
by either of the two methods illustrated, dependin.g 
upon which the operator likes the better, ( )ne of the 
flues shotdd then be sawed in half to show the quality 
of the workmanship. 



68 



TEN LESSONS IN ARC WELDING 



LESSOX IX 

Welding Steel Casliiiirs with Carbon A)( 



Tliis fxt-rcisc illustrates tlic kind nf work ddnc in a 
stet-I foundry and in certain railway shops. The car- 
bon arc is used in the same manner as the flame of an 
oxy-acet.\ lene torch, I'rom 3tK) to 600 amperes are 
iccpn'rc'd for carbon electrode work of this nature 
The- operator nuist use both hands and therefore the 
head shield is reciuired. The carbon electrode holder 
is held in the right hand and the welding rod is held 
in the left Iiand. Carbon electrode welding is nsuall> 
considered easier than metal electrode welding but 
there is eonsiclerable skill reiinired to hanclle a carlion 
are successfully. 

.Material re(|uired ; ( Ine -.mall steel casting (lig. 
141) carliiui electrode liohler. carbon electrode ' _•" in 
diameter sharpened t(] a point at one end, ,?00 amperes 
welding cajiacity (if .^(K)-ampere unit is nut available, 
twii l.stl-ampere units ma\ be ccunected in p.iralbli. 
i'.." welding re id. 

1. I'or preliminary practice the operator should usc 
the ,illl)-ampcre carbon arc and cut into small pieces 
several pieces of boiler plate scraj). I'or this work the 
arc should be held approximately a quarter of an inch 
long. After the operator has practiced sufficiently at 
this work to be able to make a clean cut along a prc- 
determine<l line, he should try welding together tun 
pieces of boiler plate scrap using the carbon arc ami 
the -lii" welding rod to fill in with. It will be rather 
difficult to control the arc and leail it in an\ desired 
direction. 

2. If iV carliiin electrodes are available one should 
be sharpened and placed in the met.al electrode hubler 




Fig. 141 



and some cutting of i',," plate d.iui' using KSt) amiarcs. 
The operator should be able to cut a straight, clean 
cut upon completing this exercise. 

.?. I'sing the riveted sample which was used in Les- 
son \'1I the operator should use the 300 amperes car- 
bon arc to cut out a section of the upper plate between 
two rivets. To perform this operation the plate should 
be set up in the same position in which it was welded 
so that when the metal is melted by the carbon arc it 
can run down out of the cut. The s.ample should then 
later be welded flush, using the metal electrode process. 
.\fter working with the carbon arc and before working 
with the metallic arc on this job it will be necessary 
to chip the oxide off the surface to be welded, since the 
larbon arc forms a very thick coating of oxide. 

4. This exercise deals with the correction of a flaw- 
in the steel casting due to a sand spot. This defect 
in the steel casting is caused by the crnmbling of the 
mold. It is necessary to burn the sand spot out with 
the carbon arc and fill in new material from the weld- 
ing rod. If there is no sand spot on the casting avail- 
able it will be sufticient for the operator to heat a spot 
approximately 1 ' j" in diameter to the molten state 
then quickly break the arc and strike the molten metal 
a sharp blow with a ball-pcin hanmier. If the operator 
had performed this operation mi a sand spot he would 
have floated nut most of the sand by the heat of the 
arc. The slLirji blou with the hammer throws the 
molten sand .and slag nut i^f the weld. The next 
the defect with new material 
The opcr.'itinn must be per- 
po^sible, ollierwisc tlie metal 
added as well .is the metal of the casting in the vicinity 
of the weld will be ruined b> the extreme heat. The 
arc should be used to cut off short pieces of the weld- 
ing rod and then these pieces should be melted and 
[luddled in the proper place. In case the arc breal<s 
durin.g the operation it should be started again on solid 
metal that is ne>t molten and the arc brought over into 
the welding area (|uickly. If the arc is started by 
touching the molten metal with the carbon electrode it 
is very likely that the weld will be hard owing to the 
fact that carbon from the electrode has gotten into 
the weld. .\s soon as the addeil m.iterial has been 
fused into the weld the arc must be broken. There 
is always a tendency on the part of .a beginner to play 
the arc too long .in the completed wehl in an attempt 
to give the weld a smooth linished appearance: this 
results in burning of the metal. In ^teel casting work 
to avoid hard spots two points must he observed: {ll 
S(mie pre-heating must be done around the point at 
which the weld is to he made with the arc so that it 
will not be cooled too suddenly. (2) The carbon 
electrode must not be brought in contact with the 
molten metal as explained before. 

This operation should be performed several times 
by the operator until he can produce a weld which is 
satisfactorv to him. 



nperation is to till 
Irom the welding rod. 
forme<l as rapidly as 



69 



TEN LESSONS IN ARC WELDING 



LESSOX X 

Cast Iron U'cldnis 



Till' piirimsc of this extToisc is to give the operatur 
an iiUa ^t what can he aeennipliNheil with the electric 
arc i>ii cast irDii The dilficuhy in uehhnt; cast iron 
with the ehctrii' arc is nut ihu' to the tact that the 
metal cannot he properly fused, hnt i> line to the fact 
tliat the- sudilen intense heat of the arc over a local 
area re-iilts in the production nf a hard weld and the 
iiUroihution ot contraction strc-^scs winch often rt'siilt 
in cr.ickmy, I sini; the carlmii welding; jirocess. ca-t 
iron wehlaij; rod- may he fn-ed into a ca-t iron piece, 
r-in'^ tile metal electrode process and a soft iron or 
steel electrode, it is impossihie to make a reliahle weld 
hetuein the added material and tile c.i-t iron. I -in^ 
the nil l.d electrnde pr^ice-s certain work can he done 
hy the introdiictimi of sttel studs in the cast iron 
pieces to he welded tiif;ether -o th.at a certain amonnt 
of strength is oht.nned hy the hoiid fi>rnn'd hetwecii 
the steel studs hy the welded m.iterial. 

.Material required: .ilVt amperes ueldni'.^ capacity, 
u," cast iron wihhnt: rod. I )ne small i^ray iron cast- 
ing (Fig. 14-'). 

A small gra\ inm casting slundd he hrokeii and the 
edges heveled, nsiii'.; the carhon arc for cutting. The 
pieces sh'inld then he |p|aced in a carhon ni(dd so that 
the molten iron when it is added will not rnii aw.i\ 
from the joint. 'Phis is illustrateil in hit;. 142. The 
carhon arc shimld he used to preheat the casting. It 
is not necessary t" heat the piece to a reil heat. The 
carl on arc and cast iron welding rod shcmld then he 
used ti' fnse the added m.iterial to the piece. .\s in 
Lesson IX, care sluaihl he exercised not to play the 
arc npoii the weld aii\ longer than is necessary to give 
complete fusion. In case the nu-tal i;ets too hot .and 
runs hadly the arc nnist he hroken ami an inter\al of 
time .ilhiwed f. ir it to cool slightly to eliminate the 
tronhle. After the wild is Completed the piece should 
lie wrapped tip secnrel\ in ashestos p.ipcr and allowed 



to coid slowly fi>r 'i or S hours (larger pieces reqnire 
from IS to 24 li.rurs to cool.) As an alternative to 
wrapping in ashestos pa]ier, the piece may he covered 
in previously heated slacked lime. The idea of the 
lime is the same as the ashestos, to cool the casting 
slowly. If the w^rk is properly pre-heated and welded 
rajiidly and ver\ slowly cooled the material in the weld 
will he as readily machineahle as the halance of the 
piece. Xo tlnx of an> kind is reipiired, although hora.x 
iiiav he nsed- 




iog, 1.12 



70 



n u u unoiDQ !iDiiniiia)iiD]inii b 



LINCOLN ARC WELDFR 



Supplies for Electric Arc 
Welding 

THE Lincoln Electric Company, while engaged primarily 
in the manufacture of electrical machinery, handles a 
complete line of supplies for electric arc welding equip- 
ment. The Company's responsibility does not end with the sale 
of electric arc welding apparatus, but covers the successful ap- 
plication of the process by the purchaser. An extensive organ- 
ization is maintained to give the purchaser of Lincoln equipment 
engineering service in connection with the application of the 
process. It has been found, after considerable experience in the 
field, that considerably better service can be rendered to the 
customer if the Company furnishes the supplies for the equip- 
ment, and thereby takes the responsibility for the supplies being 
suitable for the purchaser's use. While there is no obligation 
whatever for the purchaser of Lincoln eciuipment to use supplies 
purchased from The Lincoln Electric Company, it has been 
found by experience that when the purchaser places the entire 
responsibility for equipment and supplies with the Company, 
better results are obtained. 

The matter of welding wire is one of considerable impor- 
tance since the quality of the work and the cost of producmg it 
depends very greatly upon the kind of welding wire used. 
Owing to the wide experience of the Service Organization and 
the fact that the Company is only interested in the successful 
and satisfactory operation of the equipment, the Company ofifers 
the best welding wire which can be obtained at the lowest cost 
to the user. The welding wire which gets the results and costs 
the least money is natually the welding wire the Company 
offers the users of Lincoln equipment. 

What is true of welding wire is also true of electrode hold- 
ers, shields, protective glass and other incidental supplies. 



71 



LINCOLN ARC WELDER 




Pipes for pas ai-piiriitus hkhU- hy tin- ( «)iiiui\ i'n-, PhiI;i(U-Ii)hi;i. P; 
with I.itu olii Arc W'cMer 




Tiiiik f'.r lualitig asi'halt I..r sir.-.t rt-pairs nia.Ie I'V the l.iiunlii An. \Vt 



/ 



lUnmiuniiiuuKiiilu uu in n umi 



in n u HUH 



n mm u u u lum ' 



LINCOLN ARC WELDER 




/£Gni^eMttalz'wide 



I /6 GdifgeMebl Z''wi'de 
pdo lbs. Pail 
:^* s-f,svc lbs. pur nj^ inch. 



16 Qaif^eMeUli 'm'c/e 
-^7c lbs. Tffll" 
r£/}po Il3s.p&-sf.jnch 



/■f Cis/^eAfetdJl^'wide 
'f8,JS2. IbSfs^i-yf/hck ' 



/^ Qu^e fleti/ 2. "wide 



9pfd" lbs. 

^u/l^ -failure 
Z.I, OSO Ihs 
/oer SKJ. inch. 








^■k^ 



'.:\ 









7i 



UNCOLN HOTORS 



These mutters are nutcil tnr ilie extreme rug- 
gedness and sini]ilicity of their constructinn. 

Thev are insulated with a special ciim|i<nind 
which resists the destructive actinn of dust. dirt, 
eheniical fumes, water, heat and cold. 

On acciiunt of these features they are particu- 
larly suiable fur operating in foundries, steel 
mills, chemical plants, cottnn mills, brick and tile 
jilaiUs. shiji-xards and other places where the 
w I irking ciiuditions are exceptionally severe. 



Specifications 

r. '//(/;/.•— Standard voltages 110 to J300 volts. 
Higher \Mltages can he obtained on special order. 

I'lmscs — IWii and ihn'c ph.ise altern.iting cur- 
rent nuh'. 

Cyclrs or Frcijurni\ — J5. 30. 40. 30 and 60 
cycles per second. < )ther frequencies on special 
order. 

Sizes—' ^ to .^00 H. I'. 

'rciiif^rrnliiri' /vii/.wii/.v- - 1 -incoju .Motors are 
guaranteed to operate at a temperature rise of 
not over 40 degrees C. on continuous ftdl load 
and 55 degrees C on 25'; overlcid for two 
hours. 

(, iiaraiitrc — I^incoln Motors are guaranteed 
for a period of six months against all defects rif 
material or workmanship and we agree to re- 
I-lace free of charge f. o. b. Cleveland, parts 
which prove defective within that time, provid- 
ing the defective part is returned to us in Cleve- 
land, charges prepaid, and that inspection proves 
the claim. 

Prices and illiistratrd biillctiii on al^pHcatiou. 




Sl.Tii'Kird I.iiio.ln Motor 




Tlie Lincoln Motor has only two essential parts — the stator in 
which are mountcij the wires carrying the electric supply cur- 
rent, and the rotor or revolving part, rugged as an engine fly- 
wheel and without any hruslies. slip rings or other 
cninplicated parts. 




This Standard Lincoln Motor has ojierated under water for 
over 3 years without damage to the windings — a convincing 
proof of tlie rnggedness and reliahility t>f Lincoln con-truction. 



74 



LIBRARY OF CONGRESS 



016 091 959 % 



